Patent Publication Number: US-6704999-B2

Title: Method of and apparatus for processing photographic photosensitive film

Description:
This is a divisional of application Ser. No. 09/881,760 filed Jun.  18, 2001, ( now U.S. Pat. No. 6,490,783, issued Dec. 10, 2002), which in turn is a divisional of application Ser. No. 09/163,912, filed Oct. 1, 1998 (now U.S. Pat. No. 6,317,951, issued Nov. 20, 2001), the entire disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a method of and an apparatus for processing a photographic photosensitive film in a film producing and packaging system for unreeling a film roll of elongate photographic photosensitive film, cutting the elongate photographic photosensitive film to a film of given length, winding the cut film on a spool, and placing the wound film into a film cartridge. 
     2. Description of the Related Art 
     For producing and packaging a photographic photosensitive film, it has been customary to perform various steps including the steps of producing a film of given length, winding the film, placing the wound film into a film cartridge, and inserting the film cartridge into a case. 
     These various steps are carried out by a facility comprising a film supply unit for unwinding a film roll and cutting the unwound film to a film of given length, a film coiling unit for coiling the film of given length on a spool thereby to produce a film coil, a cartridge producing unit for staking a cap on an end of a tubular cartridge blank sheet thereby to produce a cartridge with one open end, an assembling unit for inserting the film coil into the cartridge and staking another cap on the open end of the cartridge thereby to produce an assembled cartridge, and an encasing unit for placing the assembled cartridge into a case and attaching a case cap on an open end of the case thereby to produce a packaged product. 
     If the above facility stops its operation due to any of various failures or there is a leakage of light into a dark room in the facility, then the photographic photosensitive film tends to be made defective, e.g., damaged or exposed to light. When a certain photographic photosensitive film is made defective, it has been the customary practice for the operator to discard all photographic photosensitive films in the same batch as the defective photographic photosensitive film. However, this practice is highly uneconomical. 
     There has been known a process, as disclosed in Japanese laid-open patent publication No. 6-266059, of detecting whether a photographic photosensitive film is acceptable or not, shifting a defective film signal indicative of any detected defective photographic photosensitive film in synchronism with the movement of the photographic photosensitive film, and, when the defective film signal is shifted in association with a switching position for a delivery path capable of discharging a photographic photosensitive film out of the system, switching the delivery path to automatically discharge a defective photographic photosensitive film out of the system. 
     Depending on the facility suffering a failure or the details of such a failure, a photographic photosensitive film may be subjected to a defect in a substantially long range, and it is highly time-consuming to automatically discharge a long defective film. Furthermore, if a photographic photosensitive film is twisted or jammed due to a failure of the film delivery system, then the photographic photosensitive film cannot be delivered smoothly along the delivery path. 
     The elongate photographic photosensitive film unreeled from the film roll has a plurality of perforations defined at spaced intervals in side edges thereof. When the photographic photosensitive film is to be trimmed after it has been fed to a cutting position by a predetermined length, one of the perforations may possibly be located in the cutting position. An end of the photographic photosensitive film which is to be trimmed in the cutting position will serve as a tongue of given length that projects out of an assembled cartridge. If a perforation in the film is positioned at the leading end of the tongue, then it tends to cause trouble when the film is wound in a camera. Consequently, the cartridge whose film tongue has a perforation in its leading end is poor in quality and is not acceptable as a marketable product. Because the possibility that a perforation in the film will be positioned at the leading end of the tongue is high, the percentage of defective assembled cartridges is large. This is not economical since a number of expensive cartridges have to be discarded. 
     Assembled cartridges produced by the assembling unit are tested by pulling projecting film ends, i.e., tongues, to measure the resistance to the pull. Japanese patent publication No. 5-55022, for example, discloses a device for measuring the resistance to the action to pull a projecting film end from an assembled cartridge. 
     According to the disclosed device, while an assembled cartridge is being held by an inspection turret which is continuously rotated, the resistance to the action to pull a projecting film end from the assembled cartridge is measured by a measuring unit associated with a film pulling mechanism. The measuring unit measures the resistance while the assembled cartridge is being continuously delivered. 
     When assembled cartridges are produced by the assembling unit, they are inspected in various tests in addition to the measurement of the resistance to the film end pulling action. For example, assembled cartridges are inspected to check if a cap is staked on an open end of the cartridge in which a film coil has been inserted, and also to check if the cap is properly staked on the open end. 
     Such inspecting processes need to be carried out independently in respective stations in the assembling unit. Accordingly, the assembling unit requires a relatively large working space and is highly complex in structure. Because the inspecting processes are considerably time-consuming, they are not efficient to perform. 
     SUMMARY OF THE INVENTION 
     It is a general object of the present invention to provide a method of processing a photographic photosensitive film in a manner to be able to easily and quickly discard unacceptable portions of the photographic photosensitive film which are defective due to facility failures. 
     A major object of the present invention is to provide an apparatus for processing a photographic photosensitive film in a manner to be able to reliably discard, with a simple arrangement, defective film portions including joints between photographic photosensitive films. 
     Another major object of the present invention is to provide a method of and an apparatus for processing a photographic photosensitive film while reliably and easily detecting, with a simple arrangement, whether a perforation defined in a side edge of the photographic photosensitive film is located in a cutting position or not, when films of given length are produced from the photographic photosensitive film that is unreeled from a film roll. 
     Still another major object of the present invention is to provide a method of and an apparatus for processing a photographic photosensitive film while efficiently performing various inspecting processes including a process of measuring the resistance to a pull on the photographic photosensitive film, in a reduced space and with a simple arrangement. 
    
    
     The above and other objects, features, and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic perspective view illustrative of the manner in which a packaged product is manufactured by a film producing and packaging system which carries out a method of processing a photographic photosensitive film according to a first embodiment of the present invention; 
     FIG. 2 is a schematic plan view of the film producing and packaging system; 
     FIG. 3 is a schematic side elevational view of the film producing and packaging system; 
     FIG. 4 is a side elevational view of a film supply unit of a film processing apparatus for carrying out the method of processing a photographic photosensitive film; 
     FIG. 5 is a schematic side elevational view of a succession of units ranging from the film supply unit to an assembling unit of the film producing and packaging system; 
     FIG. 6 is a perspective view of a perforation position inspecting device for carrying out the method of processing a photographic photosensitive film; 
     FIG. 7 is a vertical cross-sectional view of the perforation position inspecting device; 
     FIG. 8 is a plan view of a film of given length, showing first and second inspecting beams emitted from respective first and second inspecting units of the perforation position inspecting device; 
     FIG. 9 is an enlarged fragmentary plan view of perforations in the film in relation to the first and second inspecting beams; 
     FIG. 10 is a side elevational view of a film coiling unit and an assembling unit of the film producing and packaging system; 
     FIG. 11 is a schematic plan view of the assembling unit which carries out a resistance-to-pull inspecting process of the method of processing a photographic photosensitive film; 
     FIG. 12 is a perspective view of a resistance-to-pull inspecting device for carrying out the resistance-to-pull inspecting process; 
     FIG. 13 is an enlarged perspective view of a portion of the resistance-to-pull inspecting device; 
     FIG. 14 is a vertical cross-sectional view of a cartridge holding mechanism, a gap detector, and a height detector of the resistance-to-pull inspecting device; 
     FIG. 15 is a side elevational view, partly in cross section, of a pulling load inspecting mechanism of the resistance-to-pull inspecting device; 
     FIG. 16 is a perspective view, partly cut way, of the pulling load inspecting mechanism; 
     FIG. 17 is a block diagram of a in-factory network incorporating a film production controller for controlling the film producing and packaging system; 
     FIG. 18 is a block diagram of the in-factory network; 
     FIG. 19 is a diagram illustrative of the method of processing a photographic photosensitive film; 
     FIG. 20A is a view showing the manner in which the cartridge holding mechanism is disposed above a cartridge; 
     FIG. 20B is a view showing the manner in which the cartridge holding mechanism is lowered to the cartridge; 
     FIG. 20C is a view showing the manner in which a film end is drawn from the cartridge; 
     FIG. 21 is a diagram showing the relationship between the pulled length of the film end and the pulling load applied; and 
     FIG. 22 is a diagram illustrative of a method of processing a photographic photosensitive film according to a third embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 illustrates in schematic perspective the manner in which a packaged product  12  is manufactured by a film producing and packaging system  10  which carries out a method of processing a photographic photosensitive film according to a first embodiment of the present invention. The film producing and packaging system  10  is shown in plan and side elevation views in FIGS. 2 and 3, respectively. 
     As shown in FIGS. 1 through 3, the film producing and packaging system  10  generally comprises a film roll storage unit  17  for storing a film roll  14  of elongate photographic photosensitive film F (hereinafter referred to as elongate film F), a film supply unit  18  for unwinding the film roll  14 , cutting the unwound elongate film F into a sized film  16  of given length, and supplying the sized film  16 , a film coiling unit  22  for positioning a spool  20  and the sized film  16  relatively to each other and winding the sized film  16  on the spool  20 , a cartridge producing unit  30  for rounding a cartridge blank sheet  24  into a tubular form and staking a cap  26   a  on one end of the tubular form thereby to produce a cartridge  28  with one open end, an assembling unit  36  for inserting a film coil  32 , which is made up of the sized film  16  wound on the spool  20 , into the cartridge  28  through the open end thereof, and then staking another cap  26   b  on the open end of the cartridge  28  thereby to produce an assembled cartridge  34 , and an encasing unit  42  for placing the assembled cartridge  34  into a case  38  and attaching a case cap  40  to an open end of the case  38  thereby to produce a packaged product  12 . The film supply unit  18 , the film coiling unit  22 , and the assembling unit  36  are housed in a dark room  44 , and other devices, i.e., the encasing unit  42 , etc. are housed in a bright room  45 . 
     As shown in FIG. 2, the film supply unit  18 , the film coiling unit  22 , the assembling unit  36 , and encasing unit  42  are arrayed in line with each other along a film producing and packaging process as indicated by the arrow A. Between the dark room  44  and the bright room  45 , there extend a first straight feed path  46  for delivering cartridges  28  from the cartridge producing unit  30  to the assembling unit  36  and a second straight feed path  48  for delivering assembled cartridges  34  from the assembling unit  36  to the encasing unit  42 . 
     Downstream of the film producing and packaging process, there is disposed a parts supply apparatus  58  comprising a spool supply unit  50  for supplying spools  20  to the film coiling unit  22 , a cap supply unit  52  for supplying caps  26   b  to the assembling unit  36 , a case cap supply unit  54  for supplying case caps  40  to the encasing unit  42 , and a case supply unit  56  for supplying cases  38  to the encasing unit  42 . The spool supply unit  50 , the cap supply unit  52 , the case cap supply unit  54 , and the case supply unit  56  are closely positioned in the housing of the parts supply apparatus  58 . 
     A cap supply unit  59  for supplying caps  26   a  and a cartridge blank sheet supply unit  60  for supplying cartridge blank sheets  24  on a pallet  57  are disposed near the cartridge producing unit  30 . 
     Packaged product accumulating units  61   a ,  61   b ,  61   c  are disposed near the parts supply apparatus  58 . The packaged product accumulating units  61   a ,  61   b ,  61   c  and the encasing unit  42  are coupled to each other by a conveyor  62  which is associated with a semifinished product accumulating unit  64 . A control console  66  is disposed near the conveyor  62 . 
     As shown in FIGS. 4 and 5, the film supply unit  18  comprises a feeder  70  for holding and unwinding a film roll  14 , a splicer  72  for splicing a trailing end of the film roll  14  to a leading end of a new film roll  14 , a perforator (perforating means)  76  forming perforations  74  (see FIG. 1) in opposite longitudinal sides of an elongate film F unwound from the film roll  14 , a side printer  78  for printing latent image data on one or both of the sides of the elongate film F, and a cutter (cutting mechanism)  80  for cutting off the elongate film F to films  16  of given length. 
     The splicer  72  comprises a splicing base  82  for attracting and holding the trailing end of an elongate film F and an auxiliary base  84  for attracting and holding the leading end of a new elongate film F. The splicer  72  also has a rotatable application base  88  of square cross section for feeding a splicing tape  86 , which comprises a double-sided adhesive tape, a predetermined length in each feed cycle. The application base  88  is positioned above the splicing base  82  and vertically movable in unison with a tape cutter  92  by a cylinder  90 . 
     The perforator  76  has a fixed die block  93  and a punch block  94  disposed upwardly of the die block  93  and vertically movable by an actuator (not shown) positioned below the die block  93 . The perforator  76  also has a pair of suction chambers  96 ,  98  disposed respectively upstream and downstream of the punch block  94 . A path roller  100  and a feed roller  102  are intermittently rotatably positioned upwardly of the suction chamber  96 , and a sprocket roller  104  and a path roller  106  are intermittently rotatably positioned upwardly of the suction chamber  98 . 
     The side printer  78  comprises a first printing mechanism  112  disposed in confronting relationship to a constant-speed-feed path roller  110  and a second printing mechanism  116  disposed in confronting relationship to a constant-length-feed path roller  114 . The first printing mechanism  112  records a web-shaped print depending on the type of the film as a latent image on one or both sides of elongate films F, and the second printing mechanism  116  records a DX bar code, frame numbers, frame number bar codes, a commercial name, depending on the size of the film as latent images on one or both sides of elongate films F. 
     As shown in FIG. 5, the cutter  80  comprises a movable blade  118  and a fixed blade  120  which are disposed in vertically spaced and confronting relationship to each other, and cut the elongate film F to a predetermined length as a sized film  16  depending on the desired size of the sized film  16 . Downstream of the cutter  80 , there are disposed end feed nip rollers  122 , an openable and closable guide  124 , insertion roller pairs  126 ,  128 , and guide plates  130 ,  132 . The openable and closable guide  124  is retractable out of the film feed path. As shown in FIG. 4, a discharge port (discharge mechanism)  136  is disposed below the openable and closable guide  124  for discharging a defective film. The discharge port  136  is connected through a pipe  138  to a discharge box (not shown), and is movable in directions normal to the sheet of FIG.  4 . 
     As shown in FIGS. 4 and 5, the film supply unit  18  incorporates a discharge device  140  which serves as a film processor. The discharge device  140  comprises the splicer  72 , a trailing end position detector (trailing end position detect mechanism)  142  for detecting the trailing end of an elongate film F fully unreeled from a film roll  14  disposed closely upstream of the splicer  72 , the discharge port  136 , a splicing detector (splicing detecting mechanism)  144  disposed upstream of the cutter  80  for detecting a spliced region of elongate films F, and a film processing controller (control mechanism)  146  for discharging a preset number of elongate films F from the discharge port  136  based on a signal from the splicing detector  144 . The trailing end position detector  142  and the splicing detector  144  have respective infrared photosensors  148 ,  150 . 
     The film supply unit  18  has various detecting means for detecting various failures in the respective devices thereof. Specifically, as shown in FIG. 4, the perforator  76  has a first detecting means  152  for detecting failures produced in the perforating process, e.g., a loop failure and a bottom-dead-center failure, and the side printer  78  has a second detecting means  154  for detecting failures such as an encoder wire disconnection. A third detecting means  156  for detecting path failures such as a tension roller position failure is disposed on the film feed path of the film supply unit  18 . A photosensor  158  for detecting when the dark room  44  is in a bright condition is disposed in the dark room  44 . 
     The first, second, and third detecting means  152 ,  154 ,  156  and the photosensor  158  are connected to the film processing controller  146 , to which there is connected a timer  160  for measuring a shutdown time for the facilities. 
     A film perforation position inspecting device  161  is disposed closely upstream of the cutter  80 . As shown in FIG. 6, the film perforation position inspecting device  161  comprises first and second inspecting means  162 ,  164  arranged along a passage S and directed toward the passage S, for applying first and second inspecting beams L 1 , L 2  of light to the passage S. The perforations  74  defined in one side of the elongate film F unreeled from the film supply unit  18  in the direction indicated by the arrow B move along the passage S. 
     The first and second inspecting means  162 ,  164  comprise respective first and second infrared photosensors which comprise respective first and second light-emitting elements  166 ,  168  for applying the respective first and second inspecting beams L 1 , L 2 , which are infrared radiations, to the passage S, and respective first and second light-detecting elements  170 ,  172  positioned in confronting relation to the first and second light-emitting elements  166 ,  168 , respectively, across the elongate film F. 
     As shown in FIG. 7, an upper film guide  174  and an upper slit plate  176  are disposed below the first and second light-emitting elements  166 ,  168 , and a lower film guide  178  and a lower slit plate  180  are disposed above the first and second light-detecting elements  170 ,  172 . The upper film guide  174  and the lower film guide  178  have first and second holes  174   a ,  178   a ,  174   b ,  178   b  for passing the first and second inspecting beams L 1 , L 2 , and the upper slit plate  176  and the lower slit plate  180  have first and second holes  176   a ,  180   a ,  176   b ,  180   b.    
     The elongate film F has a thickness of 140 μm, and various dimensions as shown in FIG.  8 . Specifically, adjacent ones of the perforations  74  are spaced from each other by a distance R 1  of 4.75±0.03 mm, and each of the perforations  74  has a length R 2  of 1.98±0.02 mm. The end  182  of a trailing end (so-called “tongue”)  16   c  of the sized film  16  is spaced from a closer end  182  of the first perforation  74  by a distance T of 1.50±0.60 mm. The first and second inspecting beams L 1 , L 2  are spaced from each other by a distance R 3  of 4.75 n−R 2 +α mm. The end  182  of the trailing end  16   c  of the sized film  16  is spaced from the second inspecting beam L 2  by a distance R 4  of 4.75 n 1 −T+α/2 mm. “n” represents an integer established depending on the size of the first and second inspecting means  162 ,  164 . In this embodiment, n=3 and α=1.2 mm. “n 1 ” is an integer established depending on the size of the cutter  80  and the second inspecting means  164 . 
     As shown in FIG. 6, the first light-emitting element  166  and the first light-detecting element  170  are positioned such that when the elongate film F is accurately positioned with respect to the cutter  80 , the first inspecting beam L 1  passes through one perforation  74 . The second light-emitting element  168  and the second light-detecting element  172  are positioned such that when the elongated film F is accurately positioned with respect to the cutter  80 , the second inspecting beam L 2  passes through a perforation  74  which is spaced two perforations away from the perforation  74  through which the first inspecting beam L 1  passes. 
     Each of the first and second inspecting beams L 1 , L 2  has a beam diameter ranging from 1.0 mm to 1.5 mm. As shown in FIG. 9, each of the first and second inspecting beams L 1 , L 2  is applied as a slit-like detection beam to perforations  74 . The slit-like detection beam has a width of 0.5 mm and a length of 5 mm for increased detection accuracy. 
     The first and second light-detecting elements  170 ,  172  supply respective ON/OFF signals to a decision means  184 . The decision means  184  determines that neither one of the perforations  74  is located on the end  182 , where the elongate film F is to be severed, only when the first inspecting beam L 1  passes a perforation  74  and the second inspecting beam L 2  passes another perforation  74 . As shown in FIG. 8, no perforation  74  is located on the end  182  insofar as the elongate film F deviates from its proper position within a distance a in a direction opposite to the direction indicated by the arrow B. 
     As shown in FIGS. 4,  5 , and  10 , the film coiling unit  22  comprises a turntable  192  fixed to a main shaft  190  rotatable in the direction indicated by the arrow, a plurality of, e.g., six, spool chucks  194  mounted at equal angular intervals on the turntable  192 , a spool positioner  196  for positioning spools  20  held by the spool chucks  194 , a plurality of nip rollers  198  for pressing sized films  16  with their leading ends  16   a  inserted in the spools  20 , a prewinder  200  for prewinding the sized films  16 , and a winder  202  for winding the sized films  16  which have been prewound by the prewinder  200 . 
     A first transfer unit  208  and a second transfer unit  210  are disposed downstream of the film coiling unit  22 . The first transfer unit  208  receives a film coil  32 , which comprises a sized film  16  wound on a spool  20 , from one of the spool chucks  194 , and converts the film coil  32  from a horizontal attitude to a vertical attitude while making a 180° turn about its own axis. The first transfer unit  208  comprises a rotatable shaft  212  and a holder  214  rotatable by the rotatable shaft  212  in the direction indicated by the arrow. 
     The second transfer unit  210  comprises a turntable  218  supported by a vertical rotatable shaft  216  and rotatable about a vertical axis by the vertical rotatable shaft  216 . A plurality of vertically movable grips  220  are mounted on the turntable  218 . The second transfer unit  210  inserts a film coil  32  received from the first transfer unit  208  into a single-open-ended cartridge  28  placed on an index table  222  of the assembling unit  36 . The index table  222  is fixedly mounted on a vertical rotatable shaft  226  for indexing movement to angularly spaced positions. Chucks  228  are mounted on the index table  222  for positioning and holding single-open-ended cartridges  28  in respective stations (described below) corresponding to those angularly spaced positions. A discharge chute  230  (see FIG. 2) for discharging film coils  32  with defected films wound thereon is disposed near the second transfer unit  210 . 
     As shown in FIG. 11, the index table  222  can successively be indexed to a single-open-ended cartridge supply station ST 1 , a single-open-ended cartridge detecting station ST 2 , a film-wound spool inserting station ST 3 , a spool detecting and chuck opening station ST 4 , a cap supply station ST 5 , a chuck centering idle station ST 6 , a cap crimping station ST 7 , an idle station ST 8 , a cap height and torque detecting station ST 9 , a tongue (the trailing end  16   c  of a sized film  16 ) length detecting station ST 10 , a product unloading station ST 1  for delivering an assembled cartridge  34  from the index table  222  to the second straight feed path  48 , and a remaining cartridge detecting station ST 12  for detecting whether an assembled cartridge  34  remains on the index table  222 . 
     The single-open-ended cartridge supply station ST 1  is associated with a loading unit  232  for loading a single open-ended cartridge  28  from the first straight feed path  46  onto the index table  222 . The cap supply station ST 5  is associated with a cap feed unit  234 . The cap crimping station ST 7  is associated with a pressing unit  236 . The product unloading station ST 11  is associated with an unloading unit  238  for unloading an assembled cartridge  34  from the index table  222  to the second straight feed path  48 . 
     As shown in FIGS. 12 and 13, the cap height and torque detecting station ST 9  has a pull resistance inspecting device  240 . The pull resistance inspecting device  240  comprises a cartridge holding mechanism  242  for holding an assembled cartridge  34 , a cap detecting mechanism  244  for detecting whether there is a cap  26   b  of an assembled cartridge  34 , a height detecting mechanism  246  for detecting an increased height of the assembled cartridge  34  due to a crimping failure or the like of the cap  26   b , and a pulling load detecting mechanism  248  for detecting a load needed when the trailing end  16   c  of a sized film  16  projecting from an assembled cartridge  34  is pulled out to a predetermined length, and determining that the assembled cartridge  34  is defective if the detected load is greater than a predetermined load. 
     As shown in FIGS. 13 and 14, the cartridge holding mechanism  242  has a rod  250  vertically movable by a cam mechanism (not shown) and supported by a bearing  252 . The rod  250  supports on its lower end a holder  254  for pressing and holding a cap  26   b  crimped on the upper end of an assembled cartridge  34 . The holder  254  is of a substantially cylindrical shape and has a downwardly open central recess  255  for clearing the end of the spool  20  projecting upwardly from the assembled cartridge  34 . 
     The cap detecting mechanism  244  comprises a proximity sensor  256  embedded in a peripheral region of the holder  254 . The proximity sensor  256  serves to detect a cap  26   b , which is made of metal, of the assembled cartridge  34 . 
     To the rod  250 , there is secured an end of a height detecting plate  258  whose opposite end is disposed above a reflective photosensor (distance sensor)  262  of the height detecting mechanism  246  which is embedded in a fixed block  260 . The reflective photosensor  262  measures a distance T between itself and the height detecting plate  258  to decide whether the cap  26   b  suffers a crimping failure or not. 
     As shown in FIGS. 12 and 15, the pulling load detecting mechanism  248  comprises a gripper  270  for gripping a film end  16   c  projecting from an assembled cartridge  34 , an opening and closing unit  272  for opening and closing the gripper  270 , a back-and-forth moving unit  274  for moving the gripper  270  gripping the film end  16   c  back and forth in the directions indicated by the arrow D, and a load cell  276  for detecting a pulling load exerted when the film end  16   c  is pulled from the assembled cartridge  34  by the gripper  270 . 
     The pulling load detecting mechanism  248  has a base  278  on which a support frame  280  is vertically mounted. As shown in FIG. 15, the back-and-forth moving unit  274  includes a swing arm  282  having an end supported on the support frame  280  by a bearing  284 . The swing arm  282  is angularly movable by a cam mechanism (not shown). A slide base  286  is held in engagement with an opposite end of the swing arm  282 . 
     The slide base  286  is placed on a rail  288  mounted on the support frame  280  and extending in the directions indicated by the arrow D. A vertical attachment plate  290  is fixedly mounted on the slide base  286 , and has a relatively large opening  292  defined therein. A pair of guide rails  294   a ,  294   b  extending in the directions indicated by the arrow D is fixed respectively to upper and lower edges of the attachment plate  290 . 
     A movable plate  296  is supported on the guide rails  294   a ,  294   b  for back-and-forth movement in the directions indicated by the arrow D. The movable plate  296  has a vertical slot  298  defined therein. As shown in FIGS. 13 and 15, the gripper  270  comprises a pair of gripping fingers  302   a ,  302   b  mounted respectively on support shafts  300   a ,  300   b  that are rotatably supported on the movable plate  296 . Gears  304   a ,  304   b  which mesh with each other are fixedly supported respectively on the support shafts  300   a ,  300   b . An end of a swing rod  306  is fixed to an end of the support shaft  300   a  which is longer than the support shaft  300   b . A ball  208  is fixed to the other end of the swing rod  306 . The gripping fingers  302   a ,  302   b  have respective horizontal arms between which a coil spring  310  is connected, as shown in FIG.  12 . 
     As shown in FIGS. 15 and 16, the opening and closing unit  272  comprises a cylinder  312  mounted on the base  278  and having an upwardly extending rod  314  whose upper end is coupled to a lower end of a vertically movable plate  316 . A substantially C-shaped retainer  318  is fixed to an upper end of the vertically movable plate  316 . The ball  208  is inserted in the retainer  318 . The vertically movable plate  316  is vertically slidably supported on the support frame  280  by a guide rail  320 . 
     As shown in FIG. 13, the load cell  276  is mounted on the vertical attachment plate  290  by an angle  322  and coupled to the movable plate  296 . If a resistance detected by the load cell  276  immediately after the gripping fingers  302   a ,  302   b  pull the training end  16   c  of the sized film  16  out of the assembled cartridge  34  is 400 gf (first pulling load) or less, and a resistance detected by the load cell  276  after the gripping fingers  302   a ,  302   b  pull the training end  16   c  of the sized film  16  out of the assembled cartridge  34  by a predetermined length is 250 gf (second pulling load) or less, then the assembled cartridge  34  is determined as being accepted. 
     As shown in FIG. 2, the second straight feed path  48  extends from the dark room  44  into the bright room  45 . At a terminal end of the second straight feed path  48 , there is disposed a discharge chute  324  for automatically discharging a defective assembled cartridge  34   a  inspected in the assembling unit  36  without delivering it to the encasing unit  42 . 
     As shown in FIG. 5, the encasing unit  42  comprises an index table  328  rotatable about its own axis for indexing movement to angularly spaced positions. The index table  328  can successively be indexed to a case supply station for supplying a case  38 , a cartridge inserting station for inserting an assembled cartridge  34  into the case  38 , a cartridge detecting station for detecting whether there is an assembled cartridge  34  or not, a case cap inserting station for inserting a case cap  40  into the open end of the case  38 , a normal packaged product discharging station for discharging a normal packaged product  12 , and a defective packaged product discharging station for discharging a defective packaged product  12 . 
     FIG. 17 shows an in-factory network which incorporates the film processing controller  146  for controlling the film producing and packaging system  10 . The in-factory network includes a molding device controller  330 , a film processing controller  146 , and an outer shipping packaging device controller  332  as facility control computers which are individually controllable. 
     The forming device controller  330  sends commands to control process controllers  330   a ,  330   b ,  330   c , . . . to control various processes for operating a forming device for forming cartridge blank sheets  24  under appropriate conditions. 
     The film processing controller 146 sends commands to control process controllers  146   a ,  146   b ,  146   c,  . . . to control a process of installing a film roll  14 , inserting an assembled cartridge  34  into a case  38 , and attaching a case cap  40  to produce a packaged product  12  or a process of producing a semifinished product which is an assembled cartridge  34 . 
     The outer shipping packaging device controller  332  sends commands to control process controllers  332   a ,  332   b ,  332   c , . . . to control a process of packing packaged products  12  in a small box, wrapping the small box with a cellophane sheet, or a process of packing a given number of small boxes storing packaged products  12  in a corrugated box. 
     The forming device controller  330 , the film processing controller  146 , and the outer shipping package device controller  332 , have respective memories  334 ,  336 ,  338  which store production data obtained from the process controllers  330   a , . . .  146   a , . . .  332   a , e.g., data indicative of the numbers of products and semifinished products, data indicative of the numbers of acceptable and defective products, and inspection data from process controllers for inspection processes. 
     The forming device controller  330 , the film producing controller  146 , and the outer shipping package device controller  332 , which are facility management computers associated with respective facilities, are managed altogether by a film producing process management computer  340 , which is managed by a film manufacturing process management computer  342 , thus making up the in-factory network. The film producing process management computer  340  issues production instruction information individually to the forming device controller  330 , the film processing controller  146 , and the outer shipping packaging device controller  332 , and gives instructions for setting up conditions for processing or inspecting processes in the production facilities, to those controllers. 
     The film manufacturing process management computer  342  is supplied with production plan data, and data of loading and unloading plans or loaded and unloaded data of materials (raw materials and parts). The production plan data is supplied to the film manufacturing process management computer  342  through the control console  66 , a keyboard, or a recording medium such as a magnetic disk or the like, and stored in a memory  344 . The data of loading and unloading plans or loaded and unloaded data of materials may be supplied to the film manufacturing process management computer  342  through the control console  66 , a keyboard or a recording medium such as a magnetic disk or the like, and may also be supplied from the facility management computers. 
     A memory  346  of the film producing process management computer  340  stores as many prescription tables as the number of types of photographic film cartridges (photographic films stored in small boxes) to be manufactured. Each of these prescription tables is allotted an abbreviated product name indicative of the type of a product, and contains prescription data indicative of types of materials necessary to manufacture the photographic film cartridges of the type, manufacturing conditions, and inspecting conditions. 
     When the film manufacturing process management computer  342  is supplied with the production plan data, the film producing process management computer  340  generates a production instruction table. The production plan data comprise an order number, an abbreviated product name indicative of the type of a product to be manufactured, a planned number of products, etc. Based on the abbreviated product name contained in the production plan data, the film producing process management computer  340  searches the prescription tables, and reads all prescription data from the prescription table to which the abbreviated product name is assigned. The film producing process management computer  340  can now recognize a prescription type, a material type, material names, manufacturing conditions for operating the production facilities, and inspecting conditions therefor. If the film producing process management computer  340  confirms an inventory of materials, then the film producing process management computer  340  generates a production instruction table. The production instruction table contains a prescription type, the number of products, the names of materials to be used, manufacturing conditions, and inspecting conditions which are assigned with respect to the order number and the abbreviated product name. The items of the production instruction table include fixed items that are uniquely determined once a product type is determined and arbitrary items that can be changed. The fixed items include material names and numbers that are differently used depending on the product type, and these are automatically established. The arbitrary items include lot numbers of materials, and some manufacturing conditions and inspecting conditions, and these are arbitrarily established. 
     The production instruction table thus generated is stored altogether in the memory  346  of the film producing process management computer  340 . Data of the names of materials used, their lot numbers, the manufacturing conditions, and the inspecting conditions in the production instruction table are classified for the respective production facilities by the film producing process management computer  340 , and transmitted, together with the order number, the abbreviated product name, the prescription type, and the number of products, to the facility management computers which manage the production facilities. For example, control constants necessary to set up desired product types are transmitted to the film processing controller  146 , which sets a perforating motor speed, a constant feed rate, and a full film length detecting setting to values depending on various product types and sizes upon product type changes. 
     As described above, the film producing process management computer  340  controls the facility management computers installed respectively in combination with the production facilities through the in-factory network, i.e., the forming device controller  330 , the film processing controller  146 , and the outer shipping packaging device controller  332 , generates and stores production instruction data depending on production plan data, generates individual production instruction tables for the respective production facilities, and transmits the individual production instruction tables to the corresponding facility management computers. 
     As shown in FIG. 18, the film producing process management computer  340  manages a cutting machine controller  348  which is used as a facility management computer for a production facility. The film producing process management computer  340  manages the film processing controller  146  through a film processing information terminal  350 . 
     The cutting machine controller  348  transmits slitting conditions, e.g., established data of a feed speed of a master roll and inspecting conditions for a surface inspecting device in a cutting machine  352 , to the cutting machine  352 , thus indicating operating conditions for the cutting machine  352 . When the cutting machine  352  is operated, the master roll is severed to the same width as sized films  16 , thereby producing film rolls  14 . 
     The film manufacturing process management computer  342  stores information as to defects generated in the film manufacturing process, e.g., information as to defects on a blank film caused by a photosensitive layer coating process, into the memory  344 . The film producing process management computer  340  has a function as a cut film length number information converting means for converting the information as to defects on the blank film into information as to the number of cut film lengths from the leading end of an elongate film F unreeled from each film roll  14 . The film processing controller  146  has a function as a counting means for counting cut film lengths when the film roll  14  is unwound, and a function as a control circuit for automatically discharging the elongate film F by a length corresponding to the converted number of cut film lengths if the number of counted cut film lengths agrees with the converted number of cut film lengths. 
     Operation of the film producing and packaging system  10  will be described below with respect to the method of processing a photographic photosensitive film according to the first embodiment of the present invention. 
     In a preparatory process carried out by the film producing and packaging system  10 , a support base is coated with a photosensitive layer to produce a blank film. Defects produced on the blank film when the photosensitive layer is coated are detected by the surface inspecting device, and stored as film defect information into the memory  344  of the film manufacturing process management computer  342 . 
     The film defect information supplied from the memory  344  to the film manufacturing process management computer  342  is transmitted to the film producing process management computer  340 , which converts the film defect information into information as to the number of cut film lengths from the leading end of an elongate film F unreeled from each film roll  14  that is slitted to a given width of 35 mm, for example, from the blank film (master roll). 
     Specifically, transverse positions of defects on the blank film are stored as slitted positions, e.g., No. 1, No. 2, . . . , and longitudinal positions of the defects are stored as, for example, 100 m-200 m, 1200 m-1300 m. The film defect information is transmitted from the film manufacturing process management computer  342  to the film producing process management computer  340 . 
     The film producing process management computer  340  converts the film defect information into cut film length numbers and the numbers of cut film lengths in the longitudinal direction depending on the numbers of exposures, e.g., 12 exposures, 24 exposures, and 36 exposures, etc. For example, when 1000 24-exposure sized films  16  are manufactured from a film roll  14 , if 25th through 50th cut film lengths from the leading end of the film roll  14  are defective, then film defect information is stored as 25th through 50th cut film lengths. 
     The film producing process management computer  340  transmits the film defect information of each film roll  14  to the film processing information terminal  350 . The film processing information terminal  350  stores the number of exposures to be produced per sized film, the cut film length number, and the number of cut film lengths, and sends these items of information to the film processing controller  146 . 
     In the film supply unit  18 , as shown in FIG. 4, the feeder  70  in the film supply unit  18  is operated to rotate the film roll  14  clockwise in the direction indicated by the arrow to deliver the leading end of the unreeled new elongate film F through the splicer  72  to the perforator  76 . In the perforator  76 , the suction chambers  96 ,  98  are evacuated to attract an upstream portion of the elongate film F between the feed roller  102  and the path roller  100 , and also to attract a downstream portion of the elongate film F between the sprocket roller  104  and the path roller  106 . The elongate film F is given a predetermined tension between the sprocket roller  104  and the feed roller  102 . When the punch block  94  is vertically moved, perforations  74  are formed in opposite sides of the elongate film F by the punch block  94  in coaction with the die block  93 . 
     Then, the feed roller  102  and the sprocket roller  104  are intermittently rotated by an indexing device (not shown) to feed the elongate film F intermittently. Thereafter, the punch block  94  is vertically moved to form perforations  74  in opposite sides of the elongate film F in coaction with the die block  93 . The above perforating cycle is repeated to form a succession of perforations in opposite sides of the elongate film F at a constant pitch (see FIG.  1 ). 
     The perforated elongate film F is fed to the side printer  78  where latent images of strip-like prints depending on the film type are formed on one or both sides of the elongate film F by the first printing mechanism  112  (see FIGS.  4  and  5 ). The printed elongate film F forms a free loop between the path roller  110  and the sprocket  114 , after which the second printing mechanism  116  above the sprocket  114  records a DX bar code, frame numbers, frame number bar codes, and a commercial name, depending on the film size as latent images on one or both sides of elongate films F. 
     The elongate film F which has passed through the side printer  78  is cut by the cutter  80  to form a leading end  16   a  of a sized film  16 , and then fed in the direction indicated by the arrow B in FIG. 6 by a predetermined length corresponding to the number of exposures of the sized film  16 , after which the elongate film F is stopped. Then, the first and second inspecting means  162 ,  164  of the film perforation position inspecting device  161  are energized. 
     Specifically, the first and second light-emitting elements  166 ,  168  of the first and second inspecting means  162 ,  164  apply the respective first and second inspecting beams L 1 , L 2  to the passage S. The first inspecting beam L 1  passes through a perforation  74  and is detected by the first light-detecting element  170 , and the second inspecting beam L 2  passes through another perforation  74  and is detected by the second light-detecting element  172 . 
     The first light-detecting element  170  sends an ON signal to the decision means  184 , and the second light-detecting element  172  also sends an ON signal to the decision means  184 . The decision means  184  now determines that neither of the perforations  74  is located on the end  182 . 
     If the perforations  74  are displaced from a predetermined cutting position for the elongate film F, then the decision means  184  receives a different signal or signals from the first and second light-detecting elements  170 ,  172 . Operation of the decision means  184  based on supplied signals will be described in detail below with reference to FIG.  19  and Table 1 below. 
     
       
         
           
               
               
               
               
               
             
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                 Hole 
                 Inspecting 
                 Inspecting 
                   
               
               
                   
                 positions 
                 beam L1 
                 beam L2 
                 Judgment 
               
               
                   
                   
               
             
            
               
                   
                 P1-P2 
                 OFF 
                 OFF 
                 NG 
               
               
                   
                 P2-P3 
                 ON 
                 OFF 
                 NG 
               
               
                   
                 P3-P4 
                 ON 
                 ON 
                 OK 
               
               
                   
                 P4-P5 
                 OFF 
                 ON 
                 NG 
               
               
                   
                   
               
            
           
         
       
     
     When the perforations  74  are displaced from a normal position within the distance α as indicated between a hole position P 3  shown in FIG. 19 at (c) and a hole position P 4  shown in FIG. 19 at (d), the first inspecting beam L 1  passes through one of the perforations  74  and is detected by the first light-detecting element  170 , and the second inspecting beam L 2  passes through the other perforation  74  and is detected by the second light-detecting element  172 . Therefore, the decision means  184  is supplied with ON signals from both the first and second light-detecting elements  170 ,  172 , and determines that the positions of the perforations  170 ,  172  are OK, i.e., neither of the perforations  74  is located on the end  182 . 
     When the perforations  74  are displaced from the normal position beyond the distance a in the direction indicated by the arrow B as indicated between a hole position P 1  shown in FIG. 19 at (a), the first and second inspecting beams L 1 , L 2  are positioned between the perforations  74  and blocked by the elongate film F. Therefore, the first and second inspecting beams L 1 , L 2  are not applied to the first and second light-detecting elements  170 ,  172 , which apply OFF signals to the decision means  184 . 
     The above state is maintained until the perforations  74  are displaced to a position P 2  shown in FIG. 19 at (b). Insofar as the perforations  74  in the inspecting position are located in a range between the hole positions P 1 , P 2 , the decision means  184  determines that the positions of the perforations  74  are NG, i.e., not acceptable. When the perforations  74  in the inspecting position are located in a range between the hole positions P 2 , P 3 , the first inspecting beam L 1  passes through one of the perforations  74  and is detected by the first light-detecting element  170 , and the second inspecting beam L 2  is blocked by the elongate film F. Therefore, the decision means  184  is supplied with an ON signal from the first light-detecting means  170 , and an OFF signal from the second light-detecting means  172 . The decision means  184  determines that the positions of the perforations  74  are NG, i.e., not acceptable. 
     When the perforations  74  are largely displaced from the hole position P 4  to a hole position P 5  shown in FIG. 19 at (e) in the direction indicated by the arrow G (opposite to the direction indicated by the arrow B), the first inspecting beam L 1  is blocked by the elongate film F, and the second inspecting beam L 2  passes through one of the perforations  74  and is detected by the second light-detecting element  172 . Therefore, the decision means  184  is supplied with an OFF signal from the first light-detecting means  170 , and an ON signal from the second light-detecting means  172 . The decision means  184  determines that the positions of the perforations  74  are NG, i.e., not acceptable. 
     The elongate film F is cut to a predetermined length by the movable blade  118  and the fixed blade  120  of the cutter  80 , producing a sized film  16 . When the elongate film F is thus cut off, the trailing end  16   c  of the sized film  16  which has been severed and the leading end  16   a  of a sized film  16  to be produced next time are processed. At the same time that the leading end  16   a  of the sized film  16  to be produced next time is processed, holes for engaging a spool are also formed in the leading end  16   a.    
     A defective sized film  16  which is judged by the decision means  184  as having either perforation  74  located on the end  182  is automatically discharged while the NG signal is being shifted, as described later on. 
     The film processing controller  146  is counting film lengths cut from the elongate film F by the cutter  80 , and comparing the counted number of cut film lengths with the stored film defect information. If the counted number of cut film lengths agrees with the stored film defect information, e.g., if the 25th cut film length is detected as being disposed in the cutter  80 , then the openable and closable guide  124  is displaced away from the film feed path, and the discharge port  136  is moved onto the film feed path. 
     Then, an air blower (not shown) is actuated to cause the discharge port  136  to attract the elongate film F containing the defect. When the 50th cut film length, which is the trailing end of the defect on the elongate film F, reaches the cutter  80 , the cutter  80  is actuated to sever the elongate film F, and the length of the elongate film F which contains the defect is automatically discharged through the discharge port  136 . 
     The sized film  16  has its leading end  16   a  delivered into the film coiling unit  22 . In the film coiling unit  22 , as shown in FIGS. 5 and 10, a spool  20  is supplied to the spool chuck  194  on the turntable  192 . Then, the main shaft  190  is intermittently rotated clockwise in the direction indicated by the arrow, causing the spool positioner  196  to position the spool  20 . Upon further rotation of the turntable  192  in the direction indicated by the arrow, the leading end  16   a  of the sized film  16  is inserted into a groove  20   a  of the spool  20 . The turntable  192  is further rotated, and the prewinder  200  is operated to rotate the spool  20 . The sized film  16  whose leading end  16   a  engages the spool  20  is now prewound on the spool  20  to a predetermined length. 
     The turntable  192  is further rotated, and the winder  202  is operated to wind the sized film  16  on the spool  20 , producing a film coil  32 . After the film coil  32  is held by the holder  214  of the first transfer unit  208 , the film coil  32  is angularly moved  900  from a horizontal attitude to a vertical attitude when the holder  214  turns 180°. The film coil  32  in the vertical attitude is gripped by the grips  220  of the second transfer unit  210 . In the second transfer unit  210 , the turntable  218  rotates in unison with the vertical rotatable shaft  216 , bringing the film coil  32  gripped in the vertical attitude by the grips  220  to a standby position above the chuck  228  placed on the index table  222  of the assembling unit  36 . 
     When the second transfer unit  210  receives a film coil  32  with a sized film  16  which has been judged as defective by the decision means  184 , the second transfer unit  210  automatically discharges the defective film coil  32  through the discharge chute  230  based on an NO signal. 
     In the cartridge producing unit  30 , a cartridge blank sheet  24  is rounded, and a cap  26   a  is fitted over an end of the rounded cartridge blank sheet  24 , thus producing a single-open-ended cartridge  28 . The single-opened-ended cartridge  28  is delivered along the first straight feed path  46  to the assembling unit  36 . As shown in FIG. 11, the single-opened-ended cartridge  28  is transferred by the loading unit  232  to the single-opened-ended cartridge supply station ST 1  on the index table  222 . The index table  222  is intermittently rotated in the direction indicated by the arrow C to move the single-open-ended cartridge  28  from the single-open-ended cartridge supply station ST 1  to the film-wound spool inserting station ST 3 , in which the film coil  32  is inserted into the single-open-ended cartridge  28  by the second transfer unit  210 . 
     The single-open-ended cartridge  28  with the film coil  32  inserted therein is checked in the single-open-ended cartridge detecting station ST 2  to detect where there is a trailing end  16   c  of a sized film  16  or not. Thereafter, the single-open-ended cartridge  28  with the film coil  32  inserted therein is fed to the spool detecting and chuck opening station ST 4 . The spool detecting and chuck opening station ST 4  ascertains if the length of the trailing end  16   c  is positioned in a predetermined range or not to detect whether the film coil  32  is properly inserted in the single-open-ended cartridge  28  or not. 
     The single-open-ended cartridge  28  is then delivered to the cap supply station ST 5 . In the cap supply station ST 5 , a cap  26   b  delivered by the cap feed unit  234  is positioned in an upper open end of the single-open-ended cartridge  28 . In the cap crimping station ST 7 , the cap  26   b  is pressed into the upper open end of the single-open-ended cartridge  28  by the pressing unit  236  and crimped in place, producing an assembled cartridge  34 . The assembled cartridge  34  is then fed to the cap height and torque detecting station ST 9 . In the cap height and torque detecting station ST 9 , the cartridge holding mechanism  242 , the cap detecting mechanism  244 , the height detecting mechanism  246 , and the pulling load detecting mechanism  248  are synchronously operated. 
     Specifically, as shown in FIG. 20A, when the assembled cartridge  34  is positioned in alignment with the cartridge holding mechanism  242 , the rod  250  is lowered by the cam mechanism (not shown) until the holder  254  engages and holds the assembled cartridge  34  (see FIG.  20 B). The proximity sensor  256  of the cap detecting mechanism  244 , which is embedded in the holder  254 , detects whether there is a cap  26   b  which is made of metal or not. 
     When the rod  250  is lowered, the height detecting plate  258  with one end fixed to the rod  250  is also lowered. The distance T between the height detecting plate  258  and the fixed block  260  is detected by the reflective photosensor  262  of the height detecting mechanism  246 . If the height of the cap  26   b  is greater than a predetermined value due, for example, to a crimping failure of the cap  26   b , then the distance T detected by the photosensor  262  differs from an reference value, so that a crimping failure of the cap  26   b  can be detected. 
     With the assembled cartridge  34  held by the cartridge holding mechanism  242 , the pulling load detecting mechanism  248  is actuated. As indicated by the two-dot-and-dash lines in FIG. 15, the grips  302   a ,  302   b  of the gripper  270  are open, and the film end  16   c  of the assembled cartridge  34  is positioned in the gripper  270 . 
     The cylinder  312  of the opening and closing unit  272  is operated to cause the rod  314  to lower the vertically movable plate  316 . The ball  308  engaging the retainer  318  is swung in the direction indicated by the arrow E, causing the support shaft  300   a  connected to the swing rod  306  to turn in the direction indicated by the arrow E. The gear  304   a  fixedly mounted on the support shaft  300   a  causes the gear  304   b  meshing with the gear  304   a  to move the grips  302   a ,  302   b  angularly toward each other, i.e., in a closing direction, so that the tip ends of the grips  302   a ,  302   b  grip the film end  16   c  (see FIGS.  15  and  20 B). 
     Then, the swing arm  282  of the back-and-forth moving unit  274  is swung by the cam mechanism (not shown), thereby moving the slide base  286  coupled to the distal end of the swing arm  282  in the direction indicated by the arrow H on the support frame  280  along the rail  288 . The attachment plate  290  is fixedly mounted on the slide base  286 , and the movable plate  296  is supported on the attachment plate  290  by the guide rails  294   a ,  294   b . Therefore, when the attachment plate  290  is moved in the direction indicated by the arrow H, the gripper  270  as it grips the film end  16   c  is displaced in the direction indicated by the arrow H (see FIG.  20 C). 
     At this time, a torque for pulling the film end  16   c  acts on the gripper  270 , and the movable plate  296  on which the gripper  270  is mounted is displaced relatively to the attachment plate  290  along the guide rails  294   a ,  294   b . The load cell  276  fixed to the attachment plate  290  by the angle  322  detects a pulling load on the film end  16   c.    
     Immediately after the film end  16   c  is pulled out, there is developed a considerably large sliding resistance due to varying directions of fibers of a ribbon (not shown) mounted in the assembled cartridge  34 . It is first inspected whether or not the pulling load on the film end  16   c  immediately after the film end  16   c  starts to be pulled out is 400 gf (first pulling load) or less. After the film end  16   c  is pulled out a certain length, since the sliding resistance imposed on the film end  16   c  by the ribbon is reduced, it is inspected whether or not the pulling load on the film end  16   c  is 250 gf (second pulling load) or less. The assembled cartridge  34  which is being inspected is judged as acceptable only when the pulling load on the film end  16   c  is 400 gf or less immediately after the film end  16   c  starts to be pulled out and the pulling load on the film end  16   c  is 250 gf or less after the film end  16   c  is pulled out by the certain length. 
     After the assembled cartridge  34  is inspected by the pull resistance inspecting device  240 , the film end  16   c  is released from the gripper  270 , and the rod  250  is lifted to release the holder  254  from the assembled cartridge  34 . The assembled cartridge  34  is then delivered to the tongue length detecting station ST 10 , which detects whether the projecting length of the film end  16   c  falls within a predetermined range after the resistance to the pull on the film end  16   c  has been inspected. 
     The assembled cartridge  34  is delivered to the second feed path  48  by the unloading unit  238  (see FIG.  11 ). If the assembled cartridge  34  is judged as defective by the various inspecting processes in the assembling unit  36 , then it is automatically discharged into the discharge chute  324  without being delivered to the encasing unit  42 . If the assembled cartridge  34  is judged as accepted, then it is delivered from the second feed path  48  to the encasing unit  42 . 
     In the encasing unit  42 , a case  38  is delivered to the index table  328 , and the assembled cartridge  34  is inserted into the case  38 . Then, a case cap  40  is inserted into the open end of the case  38  in which the assembled cartridge  34  has been inserted, producing a packaged product  12 . The packaged product  12  is fed onto the conveyor  62 , from which it is introduced selectively into the packaged product accumulating units  61   a ,  61   b ,  61   c.    
     If a failure occurs in the various facilities in the film supply unit  18 , the failure is automatically detected, and a failure signal is supplied to the film processing controller  146 . For example, a loop failure or a bottom-dead-center failure in the perforator  76  is detected by the first detecting means  152 , a failure such as an encoder wire disconnection in the side printer  78  is detected by the second detecting means  154 , and a path failure such as a tension roller position failure in the film feed path is detected by the third detecting means  156 . Based on detected failure signals from these detecting means, the film processing controller  146  shuts off the film producing and packaging system  10 . 
     Then, the operator checks and restores the facility which has failed, and manually discharges the elongate film F from the facility which has failed. Specifically, depending on the facility and its failure, the operator removes a length of the elongate film F which is defective from the facility and discards the removed length. When the operator restarts the film producing and packaging system  10 , the film processing controller  146  controls the film producing and packaging system  10  to automatically discharges a length of the elongate film F which corresponds to a predetermined number of sized films from the discharge port  136 . 
     When the photosensor  158  detects a bright condition in the dark room  44 , the film producing process is interrupted. The length of the elongate film F prior to the cutter  80  is manually discarded by the operator, and all the elongate film F (and the sized films  16 ) existing in the facilities subsequent to the cutter  80  is automatically discharged. When the opening of a door by which the dark room  44  and the bright room  45  are connected is detected, the film producing process is interrupted, and the film is discharged. When a malfunction of a shutter mechanism (not shown) which separates the dark room  44  and the bright room  45  from each other is detected, the film producing process is interrupted. The operator then checks and restores the shutter mechanism, and manually discards a necessary length of the elongate film F. Thereafter, the film producing and packaging system  10  is restarted. At this time, a length of the elongate film F which corresponds to a predetermined number of sized films is automatically discharged. 
     As shown in FIG. 4, when the feeder  70  is operated to fully unreel the elongate film F from the film roll  14 , the trailing end of the elongate film F is detected by the trailing end position detector  142 . A new film roll  14  is set in the feeder  70 , and the leading end of a new elongate film F is unreeled from the new film roll  14 . In the splicer  72 , the trailing end of the fully unreeled elongate film F is attracted to the splicing base  82 , and the leading end of the new elongate film F supplied from the feeder  70  is attracted to the auxiliary base  84 . 
     After the splicing tape  86  is wound around the application base  88 , the cylinder  90  is actuated to lower the application base  88  and the tape cutter  92 . The splicing tape  86  is now applied to the trailing end of the elongated film F on the splicing base  82  across a certain width. Then, the trailing end of the elongated film F is superimposed on and applied to the leading end of the new elongated film F attracted to the auxiliary base  84 , with the splicing tape  86  interposed therebetween. 
     At this time, the film processing controller  146  controls the film producing and packaging system  10  to operate in a splicing discharge mode, and issues a command to discharge the spliced region (the splicing tape  86 ) of the trailing and leading ends of the elongate films F. Based on the command, the openable and closable guide  124  is moved away from the film feed path, and the elongate film F severed by the cutter  80  starts being drawn and discharged, from its leading end, into the discharge port  136 . 
     When the spliced region of the new and old elongate films F is detected by the splicing detector  144  disposed upstream of the cutter  80 , the new and old elongate films F are fed by a length corresponding to a predetermined number of sized films from the detected splicing region. The cutter  80  is actuated to cut off the elongate film F, and the severed elongate film F is discharged as a defective film including the spliced region from the discharge port  136 . 
     The predetermined length of the new and old elongate films F ranging from the spliced region to the severed position varies depending on the number of exposures, e.g., 12 exposures, 24 exposures, or 36 exposures, and is set to twice the number of exposures. 
     After the film producing and packaging system  10  has started operating in the splicing discharge mode, if the spliced region of the new and old elongate films F is not detected by the splicing detector  144  within a predetermined discharge length that has been established depending on the number of exposures, then such a condition is judged as a malfunction, and the film producing and packaging system  10  is automatically shut off. The predetermined discharge length is equal to 10 sized films for 12 exposures, 7 sized films for 24 exposures, and 5 sized films for 36 exposures, for example. 
     According to the first embodiment, in the film producing and packaging system  10 , when either one of the facilities suffers a failure, e.g., either one of the first, second, and third detecting means  152 ,  154 ,  156  detects a failure, the film processing controller  146  temporarily shuts off the film producing and packaging system  10 . Then, the operator repairs the facility which has failed, and manually discharges a length of the elongated film F which is judged as made defective by the failure. When the operator restarts the film producing and packaging system  10 , a length of the elongated film F equal to a preset number of sized films is automatically discharged with respect to the facility which has failed. 
     Therefore, the operator can quickly discard a desired film of the elongate film F which is likely to have been made defective by a facility failure. The process of discarding the defective length of the elongate film F is much quicker and easier than if the defective elongate film F were automatically discharged in its entirety. 
     After the defective length of the elongated film F is manually discarded by the operator, a length of the elongated film F which is equal to a preset number of sized films is automatically discharged. Consequently, any elongate film F which may possibly be defective will not remain in the film producing and packaging system  10 . As a result, high-quality films are produced and packaged using acceptable, defect-free elongate films F. 
     The timer  160  is connected to the film processing controller  146  for measuring a time in which the film producing and packaging system  10  is shut off. If the measured time exceeds a predetermined time, then when the film producing and packaging system  10  is restarted, a length of the elongate film F which is equal to a preset number of sized films is automatically discharged. In this manner, a length of the elongate film F which may possibly have been flexed or bent is reliably discarded from the film producing and packaging system  10 . 
     According to the first embodiment, furthermore, a defect produced on a blank film when the blank film is manufactured is stored by the film manufacturing process management computer  342 , and the defect information is converted into information as to the number of cut film lengths as counted from the leading end of the elongate film F unreeled from the film roll  14 . As the film roll  14  is unwound, film lengths cut from the elongate film F are counted. When the counted number of cut film lengths agrees with the converted number of cut film lengths, the position of the defect is identified. Therefore, the defect on the elongate film F can automatically and reliably be discharged through the discharge port  136 . 
     According to the first embodiment, furthermore, the trailing end of the elongate film F which has fully been unreeled from the film roll  14  is detected by the trailing end position detector  142 , and spliced to the leading end of an elongate film F to be newly unreeled by the splicer  72 . Then, when the elongate film F upstream of the cutter  80  is discharged through the discharge port  136 , the spliced region of the new and old elongate films F is detected by the splicing detector  144 . Based on a detected signal from the splicing detector  144 , the elongate film F is fed by a length corresponding to a preset number of sized films, and then severed by the cutter  80  and discharged through the discharge port  136 . Consequently, the elongate film F including the spliced region can easily and reliably be discarded under simple control with a simple arrangement. 
     According to the first embodiment, as shown in FIG. 6, with the elongate film F fed a given length toward the cutter  80  and stopped at the cutting position, the first and second inspecting means  162 ,  164  are energized to apply the first and second inspecting beams L 1 , L 2  to the passage S. Only when the first inspecting beam L 1  passes through a perforation  74  and is detected by the first light-detecting element  170 , and the second inspecting beam L 2  passes through another perforation  74  and is detected by the second light-detecting element  172 , the decision means  184  determines that neither one of the perforations  74  is located on the end  182 . 
     Therefore, for cutting (trimming) the trailing end  16   c  of the sized film  16  with the cutter  80 , it is possible to detect reliably whether perforations  74  are located on the end  182  of the trailing end  16   c . Inasmuch as defective sized films  16  are automatically discharged without being delivered to the assembling unit  36 , only assembled cartridges  34  containing defect-free sized films  16  can be produced. The outwardly projecting trailing ends  16   c  of these assembled cartridges  34  are not defective, and hence the percentage of defective assembled cartridges  34  which are produced is greatly reduced. 
     According to the first embodiment, the decision means  184  determines that the perforations  74  are properly positioned only when the first inspecting beam L 1  passes through a perforation  74  and is detected by the first light-detecting element  170 , and the second inspecting beam L 2  passes through another perforation  74  and is detected by the second light-detecting element  172 . When the first and inspecting beams L 1 , L 2  do not pass due to dust or dirt through the elongate film F, the decision means  184  always judges the elongate film F as unacceptable, but does not judge the elongate film F erroneously as acceptable. Consequently, packaged products  12  with defective sized films  16  contained therein will not be shipped from the film producing and packaging system  10 . 
     Single-open-ended cartridges  28  manufactured from cartridge blank sheets  24  are highly expensive as unit components. Since the number of assembled cartridges  34  including single-open-ended cartridges  28  which are discarded is greatly reduced, the film producing process carried out by the film producing and packaging system  10  is highly economical. 
     According to the first embodiment, furthermore, the position of the perforations  74  is inspected on the basis of ON/OFF signals produced by the first and second inspecting means  162 ,  164  each comprising a photosensor. Accordingly, the film perforation position inspecting device  161  is effectively simple and small as a whole, and can be manufactured relatively inexpensively. 
     According to the first embodiment, the pull resistance inspecting device  240  has the cartridge holding mechanism  242 , the cap detecting mechanism  244 , the height detecting mechanism  246 , and the pulling load detecting mechanism  248 . When the assembled cartridge  34  is pressed and held by the cartridge holding mechanism  242  for pulling the film end  16   c  from the assembled cartridge  34  by the pulling load detecting mechanism  248 , the cap detecting mechanism  244  and the height detecting mechanism  246  are actuated. 
     In synchronism with the operation of the cartridge holding mechanism  242  to press and hold the cartridge  34 , the proximity sensor  256  detects whether there is a cap  26   b  or not, the reflective photosensor  262  inspects the cap  26   b  for a crimping failure or the like, and the pulling load detecting mechanism  248  detects a pulling load on the film end  16   c . Consequently, the processes of detecting whether there is a cap  26   b  or not, inspecting the cap  26   b  for a crimping failure or the like, and detecting a pull resistance to the film end  16   c  are carried out substantially simultaneously in a single operation. Therefore, these inspecting processes are effected efficiently. 
     The proximity sensor  256  of the cap detecting mechanism  244  is embedded in the cartridge holding mechanism  242 , and the height detecting mechanism  246  is combined with the cartridge holding mechanism  242 . Thus, the pull resistance inspecting device  240  is highly simplified in overall arrangement. 
     The pulling load detecting mechanism  248  has the load cell  276  for detecting the pulling load on the film end  16   c  in two stages. Specifically, the load cell  276  detects whether the pulling load on the film end  16   c  is acceptable or not when the film end  16   c  is subjected to a sliding resistance (frictional resistance) imposed by the ribbon (not shown) in the cartridge  34  immediately after the film end  16   c  starts being pulled out, and also detects whether the pulling load on the film end  16   c  is acceptable or not when the film end  16   c  is pulled out by a given length and the sliding resistance imposed by the ribbon is reduced. As a result, it is possible to produce high-quality assembled cartridges  34 . 
     A method of processing a film according to a second embodiment of the present invention will be described below with reference to FIGS. 4 and 5. The method according to the second embodiment is carried out by the film producing and packaging system  10 . 
     When the trailing end of an elongate film F being delivered is detected by the trailing end position detector  142 , the trailing end of the elongate film F is spliced to the leading end of a new elongate film F from a new film roll  14  by the splicer  72 . At this time, the film processing controller  146  controls the film producing and packaging system  10  to operate in the splicing discharge mode, and issues a command to discharge the spliced region of the new and old elongate films F. Based on the command, the elongate film F is severed by the cutter  80  and then starts being drawn and discharged, from its leading end, into the discharge port  136 . 
     Based on the detected signal from the trailing end position detector  142 , the film processing controller  146  delivers the elongate film F by a predetermined discharge length depending on the number of exposures of sized films  16 . The elongate film F is then severed by the cutter  80  and then discharged from the discharge port  136 . The discharge length is equal to 10 sized films for 12 exposures, 7 sized films for 24 exposures, and 5 sized films for 36 exposures, for example. In the second embodiment, therefore, the elongate film F including the spliced region can easily and reliably be discarded under simple control with a simple arrangement. 
     After the film producing and packaging system  10  has started operating in the splicing discharge mode, if the spliced region of the new and old elongate films F is not detected by the splicing detector  144  within the predetermined discharge length that has been established depending on the number of exposures, then such a condition is judged as a malfunction, and the film producing and packaging system  10  is automatically shut off. Thus, the spliced region can be discarded more reliably. 
     A method of processing a film according to a third embodiment of the present invention will be described below with reference to FIG.  22  and Table 2. The method according to the third embodiment is carried out using the film perforation position inspecting device  161 . 
     
       
         
           
               
               
               
               
               
             
               
                   
                 TABLE 2 
               
               
                   
                   
               
               
                   
                 Hole 
                 Inspecting 
                 Inspecting 
                   
               
               
                   
                 positions 
                 beam L1 
                 beam L2 
                 Judgment 
               
               
                   
                   
               
             
            
               
                   
                   -P10 
                 OFF 
                 OFF 
                 NG 
               
               
                   
                 P10-P11 
                 OFF 
                 ON 
                 OK 
               
               
                   
                 P11-P12 
                 ON 
                 ON 
                 NG 
               
               
                   
                 P12-P13 
                 ON 
                 OFF 
                 NG 
               
               
                   
                   
               
            
           
         
       
     
     According to the third embodiment, the decision means  184  determines that neither of the perforations  74  is located on the end  182  only when the first inspecting beam L 1  is block by the elongate film F, and the second inspecting beam L 2  passes through a perforation  74 . 
     According to the third embodiment, as shown in FIG. 22, the first and second inspecting beams L 1 , L 2  are spaced from each other by a distance R 3   a  of 4.75 n 2 +H mm where n 2 =3, H=1.2 mm. 
     When the perforations  74  are displaced from a normal position by a distance H or greater as indicated by a hole position P 10  shown in FIG. 22 at (a), the first and second inspecting beams L 1 , L 2  are blocked by the elongate film F, and are not applied to the first and second light-detecting elements  170 ,  172 . Therefore, the decision means  184  is supplied with ON signals from both the first and second light-detecting elements  170 ,  172 , and determines that the positions of the perforations  170 ,  172  are NG. 
     When the perforations  74  are located within a range from the hole position P 10  to a hole position P 11  shown in FIG. 22 at (b), the second inspecting beam L 2  passes through one of the perforations  74  and is detected by the second light-detecting element  172 , and the first inspecting beam L 1  is blocked by the elongate film F. Therefore, the decision means  184  is supplied with an ON signal from the second light-detecting means  172 , and an OFF signal from the first light-detecting means  170 . The decision means  184  determines that the positions of the perforations  170 ,  172  are OK, i.e., neither of the perforations  74  is located on the end  182 . 
     When the perforations  74  are located within a range from the hole position P 11  to a hole position P 12  shown in FIG. 22 at (c), the first inspecting beam L 1  passes through one of the perforations  74  and is detected by the first light-detecting element  170 , and the second inspecting beam L 2  passes through another perforation  74  and is detected by the second light-detecting element  172 . Therefore, the decision means  184  is supplied with ON signals from both the first and second light-detecting means  170 ,  172 . The decision means  184  determines that the positions of the perforations  170 ,  172  are NG. 
     When the perforations  74  are located within a range from the hole position P 12  to a hole position P 13  shown in FIG. 22 at (d), the second inspecting beam L 2  is blocked by the elongate film F, and the first inspecting beam L 1  passes through one of the perforations  74  and is detected by the first light-detecting element  170 . Therefore, the decision means  184  is supplied with an ON signal from the first light-detecting means  170 , and an OFF signal from the second light-detecting means  172 . The decision means  184  determines that the positions of the perforations  170 ,  172  are NG. 
     According to the third embodiment, therefore, the decision means  184  determines that neither of the perforations  74  is located on the end  182  only when the first inspecting beam L 1  is block by the elongate film F, and the second inspecting beam L 2  passes through a perforation  74 . The third embodiment thus offers the same advantages as those of the first embodiment. 
     According to the present invention, as described above, in the event that the facilities of the film producing and packaging system suffer a failure, the operator repairs a failing facility and manually discharges a length of the photographic photosensitive film which may possibly be defective, after which a length of the photographic photosensitive film corresponding to a preset number of sized films is automatically discharged. The operator can thus more quickly and easily discharge the defective length of the photographic photosensitive film manually than if it were automatically discharged. When another length of the photographic photosensitive film is subsequently automatically discharged, the defective photographic photosensitive film is reliably discarded. Accordingly, it is possible to produce and package high-quality photographic photosensitive films. 
     Furthermore, after the trailing and leading ends of photographic photosensitive films are spliced, a length of the spliced photographic photosensitive film corresponding to a preset number of sized films is discharged on the basis of a detected signal representing the spliced region or a detected signal representing the trailing end. Consequently, the photographic photosensitive film including the spliced region can easily and reliably be discarded under simple control with a simple arrangement. 
     Moreover, with the photographic photosensitive film stopped in the cutting position, the first and second inspecting beams are applied to a perforated side edge of the photographic photosensitive film. It is judged whether either one of perforations is located in the cutting position by detecting whether the first and second inspecting beams pass through respective perforations in the photographic photosensitive film. Packaged products containing photographic photosensitive films in which perforations are located at severed ends thereof will be prevented from being shipped. Therefore, high-quality packaged products can efficiently be manufactured. 
     Furthermore, a process of inspecting whether a cap is mounted on a cartridge is carried out at the same time the cartridge is held in position for the purpose of pulling a film end from the cartridge. Consequently, this process and a process of inspecting a pull resistance to the film from the cartridge are conducted substantially simultaneously. The inspecting processes can thus be carried out efficiently. 
     Although certain preferred embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims.