Patent Publication Number: US-6705979-B1

Title: Method of and apparatus for machining web-shaped workpiece and apparatus for processing scrap

Description:
BACKGROUND OF THE INVENTION 
     This is a divisional of application Ser. No. 09/021,998 filed Feb. 11, 1998, the disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a method of and an apparatus for machining a web-shaped workpiece into a plurality of products, and an apparatus for processing scrap produced from such a web-shaped workpiece. 
     DESCRIPTION OF THE RELATED ART 
     Generally, machining processes of automatically manufacturing various products from web-shaped workpieces are widely carried out in factories. For example, such a machining process is employed to manufacture caps to be crimped on both ends of film cartridges which have stored photographic films, 35 mm wide, wound around spools, in a film packaging process. 
     Specifically, a web-shaped workpiece in the form of a thin metal sheet is inserted into a cap manufacturing apparatus, which is operated while the web-shaped workpiece is being intermittently fed by feed units such as nip rollers. The cap manufacturing apparatus automatically machines the web-shaped workpiece into caps to be crimped on both sides of cartridges. 
     When caps are manufactured from the web-shaped workpiece, different shapes of unwanted scrap are produced. For example, when pilot holes and burred holes are perforated in the web-shaped workpiece, circular scrap pieces of different diameters are punched out of the web-shaped workpiece. After caps have been manufactured, the web-shaped workpiece is cut off into certain lengths as scrap coils. 
     Since the various types of scrap and the caps are discharged together from the processing machine, it is a considerably complex task to sort out and collect only the caps. The caps are manually sorted out and collected, and hence cannot efficiently and automatically be obtained. 
     The film packaging process also employs a barrel plate manufacturing apparatus for manufacturing barrel plates by bending a thin metal sheet. When barrel plates are manufactured from a thin metal sheet, various pieces of scrap and defective barrel plates are also produced. The barrel plate manufacturing apparatus is combined with an apparatus for processing such various pieces of scrap. The cap manufacturing apparatus is also associated with an apparatus for processing various pieces of scrap produced when caps are manufactured. 
     Since both the barrel plate manufacturing apparatus and the cap manufacturing apparatus are associated with respective scrap processing apparatus, the entire facility is large in size and entails a large amount of cost. These problems manifest themselves particularly when a plurality of barrel plate manufacturing apparatus and a plurality of cap manufacturing apparatus are installed for mass-producing cartridges. 
     SUMMARY OF THE INVENTION 
     It is a general object of the present invention to provide a method of and an apparatus for machining a web-shaped workpiece to manufacture various products efficiently and quickly from the web-shaped workpiece. 
     Another object of the present invention is to provide an apparatus for efficiently processing various pieces of scrap produced from various machining apparatus while effectively simplifying and reducing the size of the entire facility including those apparatus. 
    
    
     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 a preferred embodiment of the present invention is shown by way of illustrative example. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of a machining apparatus according to a first embodiment of the present invention; 
     FIG. 2 is a front elevational view of the machining apparatus shown in FIG. 1; 
     FIG. 3 is a fragmentary plan view of an end portion of a thin metal sheet to be machined by the machining apparatus shown in FIG. 1; 
     FIG. 4 is a side elevational view, partly in cross section, of a workpiece feeder of the machining apparatus shown in FIG. 1; 
     FIG. 5 is a schematic view of machining sections of a processing machine of the machining apparatus shown in FIG. 1; 
     FIG. 6A is a cross-sectional view illustrative of a pilot hole machining section; 
     FIG. 6B is a cross-sectional view illustrative of a first forming section; 
     FIG. 6C is a cross-sectional view illustrative of a second forming section; 
     FIG. 6D is a cross-sectional view illustrative of a burred hole machining section; 
     FIG. 6E is a cross-sectional view illustrative of a burring section; 
     FIG. 6F is a cross-sectional view illustrative of a drawing section; 
     FIG. 6G is a cross-sectional view showing an ejected product; 
     FIG. 7 is a side elevational view of a distance detector incorporated in the machining apparatus shown in FIG. 1; 
     FIG. 8 is a perspective view of a scrap conveyor and a product conveyor incorporated in the machining apparatus shown in FIG. 1; 
     FIG. 9 is a side elevational view of an attraction conveyor of the machining apparatus shown in FIG. 1; 
     FIG. 10 is a perspective view of an elevated conveyor and a pallet conveyor of the machining apparatus shown in FIG. 1; 
     FIG. 11A is a side elevational view, partly in cross section, showing the manner in which the thin metal sheet starts being fed by the workpiece feeder; 
     FIG. 11B is a side elevational view, partly in cross section, showing the manner in which the thin metal sheet is being fed by the workpiece feeder; 
     FIG. 11C is a side elevational view, partly in cross section, showing the manner in which the workpiece feeder is returned to its original position; 
     FIG. 12 is a plan view of a machining apparatus according to a second embodiment of the present invention; 
     FIG. 13 is a front elevational view of the machining apparatus shown in FIG. 12; 
     FIG. 14 is a plan view of a parts machining line which incorporates a scrap processing apparatus according to a third embodiment of the present invention; 
     FIG. 15 is a perspective view illustrative of a processing sequence of a barrel plate manufacturing apparatus of the parts machining line shown in FIG. 14; 
     FIG. 16 is a perspective view illustrative of a processing sequence of a cap manufacturing apparatus of the parts machining line shown in FIG. 14; 
     FIG. 17 is a side elevational view, partly in cross section, of a feed mechanism of the scrap processing apparatus and a conveyor in the barrel plate manufacturing apparatus of the parts machining line shown in FIG. 14; 
     FIG. 18 is a side elevational view, partly in cross section, of the feed mechanism and another conveyor in the barrel plate manufacturing apparatus of the parts machining line shown in FIG. 14; 
     FIG. 19 is a front elevational view of the feed mechanism of the parts machining line shown in FIG. 14; 
     FIG. 20 is a front elevational view of a feed mechanism of a scrap processing apparatus according to a fourth embodiment of the present invention; and 
     FIG. 21 is a cross-sectional view taken along line XXI—XXI of FIG.  20 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in FIGS. 1 and 2, a machining apparatus  10  according to a first embodiment of the present invention generally comprises a workpiece supply  16  which accommodates workpiece rolls  14  each of a thin metal sheet  12  as an elongate web-shaped workpiece, a processing machine  20  for machining the thin metal sheet  12  into caps  18  as products, a workpiece feeder  22  for feeding the thin metal sheet  12  into the processing machine  20 , and a product feeder  26  for automatically separating the caps  18  from scrap and feeding the caps  18  to a product collecting mechanism  24 . 
     The workpiece supply  16  has first and second turntables  28 ,  30  for supporting a vertical stack of workpiece rolls  14  alternating with bases  27 . The first and second turntables  28 ,  30  are rotatable in the direction indicated by the arrows (see FIG. 1) by respective motors  31   a ,  31   b  (see FIG.  2 ). The workpiece supply  16  also has first and second posts  32 ,  34  disposed adjacent respectively to the first and second turntables  28 ,  30 . On the first post  32 , there are rotatably mounted a turning roller  36  for changing the orientation of a thin metal sheet  12  unreeled from the first turntable  28  and feeding the thin metal sheet  12  in the direction indicated by the arrow, a guide roller  38  for guiding the thin metal sheet  12 , and a pair of guide rollers  40   a ,  40   b  for guiding a thin metal sheet  12  unreeled from the second turntable  30 . A turning roller  36 , which is identical to the turning roller  36  rotatably mounted on the first post  32 , and a guide roller  38 , which is identical to the guide roller  38  rotatably mounted on the first post  32 , are rotatably mounted on the second post  34 . 
     A mount base  42  is disposed adjacent to the first turntable  28  downstream thereof with respect to the direction in which the thin metal sheet  12  is fed from the workpiece supply  16 . A clamp  44  mounted on an upper portion of the mount base  42  serves to grip one of the thin metal sheets  12  unreeled from the first and second turntables  28 ,  30 . A first guide plate  46  that is of an arcuate shape curved from a horizontal direction to a vertically downward direction is fixed to the mount base  42 . A second guide plate  50  that is of a similar arcuate shape is fixed to a wall  48  which is horizontally spaced from the first guide plate  46  downstream thereof with respect to the direction in which the thin metal sheet  12  is fed from the workpiece supply  16 . 
     The wall  48  defines a chamber  52  which accommodates the processing machine  20 . The workpiece feeder  22  and a scroll cutter  54 , which is spaced from the workpiece feeder  22  upstream with respect to the thin metal sheet  12  is fed from the workpiece supply  16  to the processing machine  20 , are mounted on the processing machine  20 . As shown in FIG. 3, the scroll cutter  54  serves to cut a leading end  12   a  of the thin metal sheet  12  prior to being machined by the processing machine  20 , thereby forming a curved edge  12   b  complementary in shape to peripheral shapes of caps  18 . 
     As shown in FIG. 4, the workpiece feeder  22  that is located downstream of the scroll cutter  54  has tables  56   a ,  56   b  for guiding a lower surface of the thin metal sheet  12  and lower and upper feeders  58 ,  60  disposed between the tables  56   a ,  56   b.    
     The lower feeder  58  has a rotatable shaft  62  which is rotatable about its own axis in the directions indicated by the arrow, and a semicircular feed face  64  mounted on the rotatable shaft  62 . The upper feeder  60  has a rotatable shaft  66  which is rotatable about its own axis in the directions indicated by the arrow and vertically movable in the directions indicated by the arrow, and a semicircular feed face  68  mounted on the rotatable shaft  66  in vertically confronting relation to the feed face  64 . A presser  70  inclined to the table  56   a  at a predetermined angle is positioned near the upper feeder  60 . The presser  70  is vertically movable toward and away from the table  56   a.    
     As shown in FIGS. 2 and 7, the processing machine  20  comprises lower and upper press dies  72 ,  74  which are vertically movable relatively to each other, and a distance detector  75  for detecting a distance S between the lower and upper press dies  72 ,  74  when the thin metal sheet  12  is machined by the lower and upper press dies  72 ,  74  in order to determine whether the thin metal sheet  12  is machined properly or not. The thin metal sheet  12  is successively machined by the lower and upper press dies  72 ,  74  while the thin metal sheet  12  is intermittently fed a predetermined distance between the lower and upper press dies  72 ,  74 . 
     As shown in FIG. 5, the lower and upper press dies  72 ,  74  have a pilot hole machining section  78  (see FIG. 6A) for forming pilot holes  76  in opposite marginal edges of the thin metal sheet  12 , an inner incising section  80  for incising the thin metal sheet  12  in patterns complementary to caps  18 , an outer incising section  82  for incising the thin metal sheet  12  in patterns outside of the incised patterns produced by the inner incising section  80 , a stamping section  84  for stamping the thin metal sheet  12 , a first forming section  86  (see FIG.  6 B), a second forming section  88  (see FIG.  6 C), a burred hole machining section  90  (see FIG. 6D) for forming a burred hole  92  in the thin metal sheet  12 , a burring section  94  (see FIG. 6E) for forming a flange on the edge of a burred hole  92  produced by the burred hole machining section  90 , a drawing section  96  (see FIG. 6F) for cutting off and drawing a cap  18 , and a product ejector  98  (see FIG. 6G) for ejecting a cap  18  formed by the drawing section  96 . These sections are successively arranged in the direction indicated by the arrow A (see FIG.  5 ). 
     As shown in FIG. 7, the distance detector  75  comprises a plurality of (six, for example) metal sensors  97  fixed to a lower die base  72   a  of the lower press die  72 , and a plurality of (six, for example) iron-base dogs  99  fixed to an upper die base  74   a  of the upper press die  74 . The metal sensors  97  and the iron-base dogs  99  are disposed in confronting pairs. The metal sensors  97  are electrically connected to a controller  101  for supplying signals representative of a detected distance S to the controller  101 . Based on the detected distance S, the controller  101  determines whether the thin metal sheet  12  is properly machined by the lower and upper press dies  72 ,  74  or not. 
     When the processing machine  20  machines the thin metal sheet  12 , it produces a first scrap  100   a  from the pilot hole  76 , a second scrap  100   b  from the burred hole  92 , a third scrap  100   c  from the drawing section  96 , and a fourth scrap  100   d  cut off the thin metal sheet  12  after caps  18  are removed. 
     As shown in FIG. 8, the processing machine  20  has a first scrap conveyor  102  extending in the direction indicated by the arrow B transversely to the direction indicated by the arrow A, for discharging the first, second, third, and fourth scraps  100   a - 100   c  severed from the thin metal sheet  12 , and a second scrap conveyor  104  extending in the direction indicated by the arrow A, for discharging the fourth scrap  100   d , which is coil scrap. The first and second scrap conveyors  102 ,  104  are coupled to a conveyor (not shown) for automatically conveying the first, second, third, and fourth scraps  100   a - 100   c  to a scrap discharge section (not shown). 
     The product feeder  26  has a product conveyor  106  (see FIG. 8) disposed in the processing machine  20 , for feeding caps  18  produced from the thin metal sheet  12  the product conveyor  106  extends in the direction indicated by the arrow B. An attraction conveyor  110  (see FIG. 9) with an elongate magnet  108  disposed therein is positioned at an end of the product conveyor  106 . 
     As shown in FIG. 9, the attraction conveyor  110  has a conveyor belt that extends through a first curved portion  112  bent vertically upwardly from a position below the end of the product conveyor  106 , a vertical portion  114  extending vertically upwardly, and a second curved portion  116  bent horizontally from an upper end of the vertical portion  114 . The conveyor belt of the attraction conveyor  110  is circulatingly operable by a motor  118  disposed in the vicinity of the second curved portion  116 . The first and second curved portions  112 ,  116  have a plurality of guide rollers  120  for guiding the conveyor belt along the curved shapes of the first and second curved portions  112 ,  116 . The magnet  108  is disposed in the looped conveyor belt and extends in the first curved portion  112 , the vertical portion  114 , and the second curved portion  116 . 
     An elevated conveyor  122  is disposed near an end of the second curved portion  116  which extends in the direction indicated by the arrow B. The elevated conveyor  122  extends in the direction indicated by the arrow A, and has a bucket  124  for receiving caps  18  from the end of the second curved portion  116 . As shown in FIG. 10, the elevated conveyor  122  has a conveyor belt circulatingly operable by a motor  126 , and a silo  128  is positioned at an end of the elevated conveyor  122  remotely from the bucket  124 . The silo  128  has an openable lid  132  at a lower end thereof. 
     A pallet conveyor  134  having a substantially C-shaped feed path as viewed in plan is disposed below the silo  128 . As shown in FIGS. 1 and 10, the pallet conveyor  134  comprises a roller conveyor  138  for feeding empty containers  136  in the direction indicated by the arrow C, which is opposite to the direction indicated by the arrow A, a motor roller conveyor  140  for feeding empty containers  136  from the roller conveyor  138  in the direction indicated by the arrow B, and a roller conveyor  144  for feeding containers  136  in the direction indicated by the arrow A after the containers  136  have received a predetermined number of caps  18  from the elevated conveyor  122  at a cap collecting position  142 . 
     Operation of the machining apparatus  10  will be described below. 
     A preparatory process carried out by the worker for making the uppermost workpiece roll  14  on the first turntable  28  ready for use with the processing machine  20  will be described below. The thin metal sheet  12  is unreeled from the uppermost workpiece roll  14 , folded over by the turning roller  36  supported on the first post  32 , and guided by the guide roller  38  toward the first guide plate  46  fixed to the mount base  42 . 
     The thin metal sheet  12  is then guided by the second guide plate  50  into the chamber  52 , whereupon the leading end  12   a  of the thin metal sheet  12  is cut by the scroll cutter  54 , forming a curved edge  12   b  in the thin metal sheet  12  (see FIG.  3 ). The thin metal sheet  12  with the curved edge  12   b  is then inserted between the lower and upper feeders  58 ,  60  of the workpiece feeder  22 . 
     The preparatory process is now finished, and the machining apparatus  10  starts operating. The first turntable  28  is rotated in the direction indicated by the arrow in FIG. 1 to feed the thin metal sheet  12  unreeled from the uppermost workpiece roll  14 . The thin metal sheet  12  thus fed forms a loop between the first and second guide plates  46 ,  50 . 
     The rotatable shafts  62 ,  66  of the lower and upper feeders  58 ,  60  are synchronously rotated respectively in the directions indicated by the arrows D, E in FIG. 11A, and the presser  70  is moved in a direction away from the thin metal sheet  12 . The thin metal sheet  12  is now fed in the direction indicated by the arrow A (see FIG. 11B) while being gripped between the feed faces  64 ,  68  of the lower and upper feeders  58 ,  60 . The rotatable shafts  62 ,  66  are stopped after they have rotated a predetermined angle. 
     Then, the rotatable shaft  66  of the upper feeder  60  is moved in a direction away from the thin metal sheet  12 , after which the rotatable shafts  62 ,  66  start rotating in the opposite directions, i.e., in the respective directions indicated by the arrows F, G in FIG.  11 C. The presser  70  is moved toward the table  56   a , gripping the thin metal sheet  12  between the table  56   a  and the tip end of the presser  70 . The lower and upper feeders  58 ,  60  are thus reversed to a predetermined feeding start position without damage to the thin metal sheet  12 , and the thin metal sheet  12  is held against movement in the direction indicated by the arrow C because it is gripped between the table  56   a  and the tip end of the presser  70 . The above operation of the workpiece feeder  22  is repeated to intermittently feed the thin metal sheet  12  a predetermined distance into the processing machine  20 . 
     In the processing machine  20 , the lower and upper press dies  72 ,  74  move toward and away from each other while the thin metal sheet  20  is being intermittently fed in the direction indicated by the arrow A. As shown in FIG. 5, pilot holes  76  are punched in opposite marginal edges of the thin metal sheet  12  by the pilot hole machining section  78 , producing a first scrap  100   a  (see FIG.  6 A). Then, the thin metal sheet  12  is incised successively by the inner incising section  80  and the outer incising section  82 , and then stamped by the stamping section  84 , after which the thin metal sheet  12  is processed by the first forming section  86  (see FIG.  6 B). 
     After having been processed by the first forming section  86 , the thin metal sheet  12  is processed by the second forming section  88  (see FIG.  6 C). Then, a burred hole  92  is formed in the thin metal sheet  12  by the burred hole machining section  90 , producing a second scrap  100   b  (see FIG.  6 D). A flange is formed on the edge of the burred hole  92  by the burring section  94  (see FIG.  6 E). The drawing section  96  then cuts off and draws a cap  18  (see FIG.  6 F), producing a third scrap  100   c.    
     The thin metal sheet  12  is then fed to the product ejector  98 , which removes the cap  18  as a product from the thin metal sheet  12  (see FIG.  6 G). Thereafter, the thin metal sheet  12  is cut off into a predetermined length, which is produced as a fourth scrap  100   d.    
     When the thin metal sheet  12  is machined by the lower and upper press dies  72 ,  74  as described above, the distance S between the lower and upper press dies  72 ,  74  as they are positioned mostly closely to each other is successively detected by the metal sensor  97  and the dog  99  of the distance detector  75 , as shown in FIG.  7 . 
     The controller  101  reads the distance S from the metal sensor  97 , calculates the difference between the latest distance reading and a preceding distance reading, and also calculates the difference between the latest distance reading and an average value of previous four distance readings. The controller  101  displays a greater distance reading difference on a display monitor unit (not shown). If the greater distance reading difference is larger than a predetermined value, then the controller  101  produces a fault signal. When the fault signal is issued, the worker may shut off the machining apparatus  10  and take necessary actions to remove a fault condition that has caused the greater distance reading difference to be larger than the predetermined value. Accordingly, it is possible to prevent the thin metal sheet  12  from being improperly machined due to chips or other foreign matter introduced into the processing machine  20  or from being improperly fed. 
     As shown in FIG. 8, the first, second, and third scraps  100   a - 100   c  are delivered to the first scrap conveyor  102  and fed thereby in the direction indicated by the arrow B, and the fourth scrap  100   d  is delivered to the second scrap conveyor  104  and fed thereby in the direction indicated by the arrow A. Thereafter, the first, second, third, and fourth scraps  100   a - 100   d  are delivered to the non-illustrated conveyor, by which they are automatically discharged into the scrap discharge section. 
     The cap  18  is delivered to the product conveyor  106 , which feeds the cap  18  in the direction indicated by the arrow B. As shown in FIG. 9, the cap  18  is then dropped onto the first curved portion  112  of the attraction conveyor  110  whose conveyor belt is being circulatingly moved by the motor  118 . The cap  18  supplied to the first curved portion  112  is fed from the first curved portion  112  vertically upwardly along the vertical portion  114  and then horizontally along the second curved portion  116  while being magnetically attracted by the magnet  108 . 
     The cap  18  is then introduced from the horizontal end of the second curved portion  116  into the bucket  124 , from which the cap  18  drops onto the end of the elevated conveyor  122  disposed underneath the bucket  124  and whose conveyor belt is being circulatingly moved by the motor  126 . As shown in FIG. 10, the cap  18  dropped onto the end of the elevated conveyor  122  is fed in the direction indicated by the arrow A and then supplied from the other end of the elevated conveyor  122  into the silo  128 . 
     On the pallet conveyor  134  disposed beneath the silo  128 , an empty container  136  positioned on one end of the roller conveyor  138  is fed thereby in the direction indicated by the arrow C, and transferred to the motor roller conveyor  140 . The empty container  136  is fed in the direction indicated by the arrow B by the motor roller conveyor  140 , and then fed in the direction indicated by the arrow A into the cap collecting position below the silo  128  by the roller conveyor  144 . When the empty container  136  is in the cap collecting position below the silo  128 , the lid  132  is opened by a cylinder  130 , allowing a predetermined number of caps  18  to fall from the silo  128  into the container  136 . After the predetermined number of caps  18  are supplied to the container  136 , the container  136  is fed in the direction indicated by the arrow A by the roller conveyor  144 , and then unloaded from the end of the roller conveyor  144 . 
     When the remaining length of the thin metal sheet  12  unreeled from the uppermost workpiece roll  14  on the first turntable  28  becomes small, another thin metal sheet  12  unreeled from the uppermost workpiece roll  14  on the second turntable  30  and gripped by the clamp  44  will be supplied to the processing machine  20 . While the thin metal sheet  12  unreeled from the first turntable  28  is being machined by the processing machine  20 , the thin metal sheet  12  is unreeled from the uppermost workpiece roll  14  on the second turntable  30  and supplied through the turning roller  36  and the guide rollers  38 ,  40   a ,  40   b  with its leading end gripped by the clamp  44 . 
     When the uppermost workpiece roll  14  on the first turntable  28  is used up, the thin metal sheet  12  gripped by the clamp  44  is quickly fed into the processing machine  20  and machined thereby. During this time, a thin metal sheet  12  is unreeled from a next workpiece roll  14  on the first turntable  28  and its lead end is gripped by the clamp  44 . 
     In the first embodiment, as described above, the workpiece feeder  22  for feeding the thin metal sheet  12  in the direction indicated by the arrow A is positioned upstream of the processing machine  20 . For making the thin metal sheet  12  ready for being supplied to the processing machine  20 , it is only necessary to unreel the thin metal sheet  12  from the workpiece roll  14 , form the curved edge  12   b  in the thin metal sheet  12  with the scroll cutter  54 , and then insert the thin metal sheet  12  between the lower and upper feeders  58 ,  60  of the workpiece feeder  22 . 
     Unlike a feed mechanism disposed downstream of the processing machine  20  for pulling the thin metal sheet  12 , the workpiece feeder  22  does not require the worker to insert the thin metal sheet  12  between the lower and upper press dies  72 ,  74  of the processing machine  20 . Accordingly, the preparatory process for preparing the thin metal sheet  12  for supply to the processing machine  20  is highly easy and efficient to perform. 
     The first, second, third, and fourth scraps  110   a - 11   c  which are produced when the thin metal sheet  12  is machined by the processing machine  20  are discharged onto the first and second scrap conveyors  102 ,  104 , and the cap  18  is delivered onto the product conveyor  106 . The cap  18  is then supplied from the product conveyor  106  through the attraction conveyor  110  to the elevated conveyor  122  and the silo  128 . In this manner, a predetermined number of caps  18  are automatically collected into the container  136 . Consequently, the process of operation from the unreeling of the thin metal sheet  12  to the collection of the caps  18  is carried out automatically and efficiently. 
     The attraction conveyor  110  which incorporates the magnet  108  makes it possible to feed the cap  18  reliably in various directions, particularly vertically. Therefore, the product collecting mechanism  24  may be positioned as desired, making the machining apparatus  10  adaptable to various layout modifications. 
     The scroll cutter  54  is disposed upstream of the processing machine  20  for forming the curved edge  12   b  in the leading end  12   a  of the thin metal sheet  12 . When the thin metal sheet  12  is machined by the processing machine  20 , therefore, no scrap is produced from the leading end  12   a  of the thin metal sheet  12  because of the shape of caps  18 . As a result, caps  18  can be produced from the thin metal sheet  12  efficiently with a high yield. 
     FIGS. 12 and 13 show a machining apparatus  160  according to a second embodiment of the present invention. 
     As shown in FIGS. 12 and 13, the machining apparatus  160  generally comprises a workpiece supply  16  which accommodates workpiece rolls  14  each of a thin metal sheet  12  as a web-shaped workpiece, a processing machine  20  for machining the thin metal sheet  12  into caps  18  as products, a workpiece feeder  162  disposed downstream of the processing machine  20  with respect to the direction (indicated by the arrow A) in which the thin metal sheet  12  is fed, for feeding the thin metal sheet  12  into the processing machine  20 , and a product feeder  26  for automatically separating the caps  18  from scrap and feeding the caps  18  to a product collecting mechanism  24 . 
     The workpiece supply  16 , the processing machine  20 , and the product feeder  26  shown in FIGS. 12 and 13 are identical to the workpiece supply  16 , the processing machine  20 , and the product feeder  26  of the machining apparatus  10  according to the first embodiment. 
     The workpiece feeder  162  is identical to the workpiece feeder  22  according to the first embodiment. A workpiece delivery unit  164  is disposed upstream of the processing machine  20  with respect to the direction indicated by the arrow A, for delivering the thin metal sheet  12  from the processing machine  20  to the workpiece feeder  162 . The workpiece delivery unit  164  is identical to the workpiece feeder  22  according to the first embodiment. 
     Those parts of the machining apparatus  160  which are identical to those of the machining apparatus  10  are denoted by identical reference characters, and will not be described in detail below. 
     In the machining apparatus  160 , the leading end  12   a  of the thin metal sheet  12  unreeled from the workpiece roll  14  on the first turntable  28  is cut off by the scroll cutter  54 . Then, the thin metal sheet  12  is inserted between the lower and upper press dies  72 ,  74  by the workpiece delivery unit  164 , and thereafter inserted between the lower and upper feeders  58 ,  60  of the workpiece feeder  162 . 
     After the preparatory process performed by the worker is finished, the machining apparatus  160  starts operating to machine the thin metal sheet  12 . The workpiece feeder  162  is operated to intermittently feed the thin metal sheet  12  through the processing machine  20  while the thin metal sheet  12  is being successively machined by the processing machine  20 . 
     In the second embodiment, various pieces of scrap produced when the thin metal sheet  12  is machined by the processing machine  20  are discharged onto the first and second scrap conveyors  102 ,  104 , and the cap  18  is delivered onto the product conveyor  106 . Consequently, the process of operation from the unreeling of the thin metal sheet  12  to the collection of the caps  18  is carried out automatically and efficiently, as is the case with the first embodiment. 
     According to the second embodiment, furthermore, the processing machine  20  is combined with the workpiece delivery unit  164  disposed upstream of the processing machine  20  for delivering the thin metal sheet  12  into the processing machine  20  and the workpiece feeder  162  disposed downstream of the processing machine  20  for intermittently feeding the thin metal sheet  12  to the processing machine  20 . The workpiece delivery unit  164  and the workpiece feeder  162  are jointly effective in smoothly delivering the thin metal sheet  12 , which may be highly thin, into the processing machine  20  and also stably and reliably intermittently feeding the thin metal sheet  12 . 
     In the first and second embodiments, the workpiece feeders  22 ,  162  and the workpiece delivery unit  164  may comprise commercially available air feeders or the like for chucking and intermittently feeding the thin metal sheet  14  in the direction indicated by the arrow A. The scroll cutter  54  may be positioned downstream of the workpiece feeder  22  or the workpiece delivery unit  164 , and after the thin metal sheet  12  is gripped by the workpiece feeder  22  or the workpiece delivery unit  164 , the leading end  12   a  of the thin metal sheet  12  may be cut off by the scroll cutter  54 , and then the thin metal sheet  12  may automatically be delivered into the processing machine  20 . 
     FIG. 14 shows a parts machining line  212  which incorporates a scrap processing apparatus  210  according to a third embodiment of the present invention. 
     As shown in FIG. 14, the parts machining line  212  comprises first and second barrel plate manufacturing apparatus  216 ,  218  (first machining apparatus) juxtaposed on a floor  214  and spaced from each other in the direction indicated by the arrow D, first and second cap manufacturing apparatus  220 ,  222  (second machining apparatus) juxtaposed on the floor  214  and spaced from each other in the direction indicated by the arrow E transversely to the direction indicated by the arrow D, and the scrap processing apparatus  210 . 
     As shown in FIG. 15, each of the first and second barrel plate manufacturing apparatus  216 ,  218  comprises a thin sheet supply station ST 1 , a corner cutting station ST 2 , a step bending station ST 3 , an end folding station ST 4 , an end bending station ST 5 , and a ribbon-applying station ST 6 . 
     The thin sheet supply station ST 1  contains a stack of thin metal sheets (first workpiece)  224  to be processed into barrel plates. The thin sheet supply station ST 1  supplies one at a time of the stacked thin metal sheets  224 . The corner cutting station ST 2  cuts off the four corners of the supplied thin metal sheet  224 , forming respective steps  226 . The step bending station ST 3  bends the steps  226  at a small radius R. The end folding station ST 4  folds an end  224  of the thin metal sheet  224 . The end bending station ST 5  bends the folded end  224   a  and an opposite end  224   b  of the thin metal sheet  224  with a press. The ribbon-applying station ST 6  applies velveted ribbons  227  respectively to the ends  224   a ,  224   b  of the thin metal sheet  224 , producing a barrel plate (first product)  228 . 
     As shown in FIG. 15, when each of the first and second barrel plate manufacturing apparatus  216 ,  218  produces the barrel plate  228  from the thin metal sheet  224 , first, second, and third scraps  230   a ,  230   b ,  230   c  (first scrap member) are generated. The third scrap  230   c  is a barrel plate  228  which is judged as defective and unacceptable by an inspection process after velveted ribbons  227  are applied to the thin metal sheet  224  by the ribbon-applying station ST 6 . 
     As shown in FIG. 14, each of the first and second cap manufacturing apparatus  220 ,  222  comprises a workpiece supply  234  which accommodates workpiece rolls  233  each of a thin metal sheet (second workpiece)  232  as a web-shaped workpiece, and a processing machine  236  for machining the thin metal sheet  232  unreeled from one of the rolls  233 . 
     As shown in FIG. 16, the processing machine  236  comprises a pilot hole machining station ST 1   a  for forming pilot holes  238  in opposite marginal edges of the thin metal sheet  232 , an inner incising station ST 2   a  for incising the thin metal sheet  238  in patterns complementary to caps (second product)  240 , an outer incising station ST 3   a  for incising the thin metal sheet  232  in patterns outside of the incised patterns produced by the inner incising station ST 2   a , a stamping station ST 4   a  for stamping the thin metal sheet  232 , a first forming station ST 5   a , a second forming station ST 6   a , a burred hole machining station ST 7   a  for forming a burred hole  242  in the thin metal sheet  232 , a burring station ST 8   a  for forming a flange on the edge of a burred hole  242  produced by the burred hole machining station ST 7   a , a drawing station ST 9   a  for cutting off and drawing a cap  240 , a product ejecting station ST 10   a  for ejecting a cap  240  formed by the drawing station ST 9   a , and a cutting station ST 11   a  for cutting off the thin metal sheet  232  into a coil scrap having a predetermined length. 
     When the pilot hole machining station ST 1   a  forms pilot holes  238  in opposite marginal edges of the thin metal sheet  232 , the pilot hole machining station ST 1   a  produces a fourth scrap (second scrap member)  244   a . When the burred hole machining station ST 7   a  forms a burred hole  242  in the thin metal sheet  232 , the burred hole machining station ST 7   a  produces a fifth scrap (second scrap member)  244   b . When the cutting station ST 11   a  cuts off the thin metal sheet  232 , the cutting station ST 11   a  produces a sixth scrap (second scrap member)  244   c  as a coil scrap. 
     As shown in FIG. 14, the scrap processing apparatus  210  has a pair of first discharge mechanisms  250  extending in the direction indicated by the arrow E along the first and second barrel plate manufacturing apparatus  216 ,  218 , for discharging the first, second, and third scraps  230   a - 230   c  produced by the first and second barrel plate manufacturing apparatus  216 ,  218 , a second discharge mechanism  252  extending in the direction indicated by the arrow E along the first and second cap manufacturing apparatus  220 ,  222 , for discharging the fourth, fifth, and sixth scraps  244   a - 244   c  produced by the first and second cap manufacturing apparatus  220 ,  222 , a feed mechanism  254  for feeding in the direction indicated by the arrow D 1  the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  which are discharged by the first and second discharge mechanisms  250 ,  252 , and a scrap collecting mechanism  256  for collecting the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  which are fed by the feed mechanism  254 . 
     Each of the first discharge mechanisms  250  comprises a first conveyor  258  for discharging the first scrap  230   a  produced by the first and second barrel plate manufacturing apparatus  216 ,  218  into the feed mechanism  254 , and a second conveyor  260  for discharging the second and third scraps  230   b ,  230   c  into the feed mechanism  254 . As shown in FIGS. 17 and 18, guide plates  274 ,  276  are disposed at ends of the first and second conveyors  258 ,  260  near the feed mechanism  254  for preventing the first, second, and third scraps  230   a - 230   c  from becoming jammed in feed chains of the feed mechanism  254 . 
     As shown in FIG. 14, the second discharge mechanism  252  comprises third conveyors  280   a ,  280   b  for discharging the fourth and fifth scraps  244   a ,  244   b  from the first and second cap manufacturing apparatus  220 ,  222 , fourth conveyors  282   a ,  282   b  for discharging the sixth scrap  244   c  from the first and second cap manufacturing apparatus  220 ,  222 , and fifth conveyors  284   a ,  284   b  extending in the direction indicated by the arrow E for discharging the fourth, fifth, and sixth scraps  244   a - 244   c  into the feed mechanism  254 . 
     As shown in FIGS. 14,  17 - 19 , the feed mechanism  254  comprises a pit  290  defined in the floor  214 , a swing conveyor  292  disposed in the pit  290 , and a slanted conveyor  294  extending from an end of the swing conveyor  292  obliquely upwardly toward the scrap collecting mechanism  256 . 
     The swing conveyor  292  extends in the direction indicated by the arrow D from the first and second barrel plate manufacturing apparatus  216 ,  218  into the first and second cap manufacturing apparatus  220 ,  222 . The slanted conveyor  294  has a circulatory endless conveyor belt  298  and an elongate magnet  300  disposed in the conveyor belt  298 . A chute  302  is disposed below an upper end of the slanted conveyor  294 , and a movable cart  304  is positioned underneath the chute  302 . 
     Operation of the scrap processing apparatus  210  in relation to the parts machining line  212  will be described below. 
     In each of the first and second barrel plate manufacturing apparatus  216 ,  218 , as shown in FIG. 15, one at a time of the stacked thin metal sheets  224  is supplied from the thin sheet supply station ST 1  to the corner cutting station ST 2 . In the corner cutting station ST 2 , the four corners of the supplied thin metal sheet  224  are cut off, forming respective steps  226  and discharging second scraps  230   b . The thin metal sheet  224  with the steps  226  is fed to the step bending station ST 3 . In the step bending station ST 3 , the steps  226  are bent at a small radius R. 
     The thin metal sheet  224  is then delivered from the step bending station ST 3  to the end folding station ST 4 . After the end  224   a  of the thin metal sheet  224  is folded in the end folding station ST 4 , the thin metal sheet  224  is supplied to the end bending station ST 5 . In the end bending station ST 5 , the ends  224   a ,  224   b  of the thin metal sheet  224  are bent by a press. If the thin metal sheet  224  machined by the end bending station ST 5  is judged as acceptable by an inspection process, then the thin metal sheet  224  is sent to the ribbon-applying station ST 6 . In the ribbon-applying station ST 6 , velveted ribbons  227  are applied to the respective ends  224   a ,  224   b  of the thin metal sheet  224 . If the thin metal sheet  224  machined by the end bending station ST 5  is judged as defective, then the thin metal sheet  224  is ejected as the third scrap  230   c.    
     While the barrel plate  228  is being manufactured in each of the first and second barrel plate manufacturing apparatus  216 ,  218 , the second and third scraps  230   b ,  230   c  and the first scrap  230   a  that is produced when the thin metal sheet  224  is formed to desired shape are generated in a large quantity. 
     As shown in FIGS. 14 and 17, the first scrap  230   a  is delivered to the feed mechanism  254  by the first conveyor  258 , and discharged onto the swing conveyor  292  of the feed mechanism  254  by being guided by the guide plates  274 . As shown in FIG. 18, the second and third scraps  230   b ,  230   c  are discharged from the second conveyor  260  onto the swing conveyor  292  by being guided by the guide plate  276 . 
     In each of the first and second cap manufacturing apparatus  220 ,  222 , the thin metal sheet  232  is fed from one of the workpiece rolls  233  in the workpiece supply  234  to the processing machine  236 . In the processing machine  236 , as shown in FIG. 16, the thin metal sheet  232  is intermittently fed in the direction indicated by the arrow F. In the pilot hole machining station ST 1   a , pilot holes  238  are formed in opposite marginal edges of the thin metal sheet  232 , producing a fourth scrap  244   a.    
     Then, the thin metal sheet  232  is machined successively by the inner incising station ST 2   a , the outer incising station ST 3   a , and the stamping station ST 4   a , after which the thin metal sheet  232  is processed by the first forming station ST 5   a . After having been processed by the first forming station ST 5   a , the thin metal sheet  232  is processed by the second forming station ST 6   a . Then, the thin metal sheet  232  is fed to the burred hole machining station ST 7   a , in which a burred hole  242  is formed in the thin metal sheet  232 , producing a fifth scrap  244   b.    
     A flange is formed on the edge of the burred hole  242  by the burring station ST 8   a . The thin metal sheet  232  is fed to the drawing station ST 9   a  which cuts off and draws a cap  240 . In the product ejecting station ST 10   a , the cap  240  is removed from the thin metal sheet  232 . Thereafter, the thin metal sheet  232  is cut off into a predetermined length as a sixth scrap  244   c  by the cutting station ST 11   a.    
     As shown in FIG. 14, the fourth and fifth scraps  244   a ,  244   b  are discharged via the third conveyors  280   a ,  280   b  onto the fifth conveyors  284   a ,  284   b , and the sixth scrap  244   c  is discharged via the fourth conveyors  282   a ,  282   b  onto the fifth conveyors  284   a ,  284   b . The fourth, fifth, and sixth scraps  244   a - 244   c  are discharged from the fourth conveyors  282   a ,  282   b  onto the swing conveyor  292  of the feed mechanism  254 . 
     The swing conveyor  292  feeds the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  in the direction indicated by the arrow D 1  toward the scrap collecting mechanism  256 , and then, as shown in FIG. 19, delivers the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  onto the slanted conveyor  294  disposed closely to the end of the swing conveyor  292 . The first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  which are supplied to the slanted conveyor  294  are fed obliquely upwardly by the endless belt  298  while being magnetically attracted by the magnet  300 , and then dropped from the upper end of the slanted conveyor  294  into the chute  302 . 
     The chute  302  has a manual distribution chute (not shown) which discharges a predetermined number of the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  into the movable cart  304  that is positioned below the chute  302 . When the loaded movable cart  304  is moved away from the position below the chute  302 , another empty movable cart  304  is moved into the position below the chute  302 . 
     In the third embodiment, the feed mechanism  254  is integrally combined through the first and second discharge mechanisms  250 ,  252  with the first and second barrel plate manufacturing apparatus  216 ,  218  which manufacture barrel plates  228  and the first and second cap manufacturing apparatus  220 ,  222  which manufacture caps  240 . The first, second, and third scraps  230   a - 230   c  produced by the first and second barrel plate manufacturing apparatus  216 ,  218  and the fourth, fifth, and sixth scraps  244   a - 244   c  produced by the first and second cap manufacturing apparatus  220 ,  222  are delivered by the swing conveyor  292  of the common feed mechanism  254  toward the scrap collecting mechanism  256 , and then collected into the movable cart  304  removably placed in the scrap collecting mechanism  256 . 
     As described above, the scrap processing apparatus  210  is capable of processing both the first, second, and third scraps  230   a - 230   c  produced by the first and second barrel plate manufacturing apparatus  216 ,  218  and the fourth, fifth, and sixth scraps  244   a - 244   c  produced by the first and second cap manufacturing apparatus  220 ,  222 . Consequently, the parts machining line  212  is smaller in size, simpler in structure, and lower in cost than conventional parts machining lines where the first and second barrel plate manufacturing apparatus  216 ,  218  and the first and second cap manufacturing apparatus  220 ,  222  would need respective dedicated scrap processing apparatus. 
     Furthermore, the single feed mechanism  254  is shared by the first and second barrel plate manufacturing apparatus  216 ,  218  and the first and second cap manufacturing apparatus  220 ,  222 . The entire facility is thus relatively small in size, and capable of processing scrap efficiently with ease. 
     In the third embodiment, moreover, the swing conveyor  292  of the feed mechanism  254  is disposed in the pit  290  defined in the floor  214 . This layout provides an extra space above the swing conveyor  292 , which can effectively be used for another purpose in the factory in which the parts machining line  212  is installed. The slanted conveyor  294 , which is joined to the end of the swing conveyor  292  near the scrap collecting mechanism  256 , feeds the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  to an upper position in the factory, from which the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  are dropped into the movable cart  304  in the scrap collecting mechanism  256 . The movable cart  304  can easily be handled because it is only required to be removably positioned in the scrap collecting mechanism  256  on the floor  214 . 
     In the third embodiment, the scrap processing apparatus  210  is integrally combined with the first and second barrel plate manufacturing apparatus  216 ,  218  (first machining apparatus) and the first and second cap manufacturing apparatus  220 ,  222  (second machining apparatus). However, the scrap processing apparatus  210  may be integrally combined with first through Nth (N=an integer of 3 or more) machining apparatus. 
     FIGS. 20 and 21 show a feed mechanism  322  of a scrap processing apparatus  320  according to a fourth embodiment of the present invention. Those parts of the scrap processing apparatus  320  which are identical to the scrap processing apparatus  210  according to the third embodiment are denoted by identical reference characters, and will not be described in detail below. 
     As shown in FIG. 20, the feed mechanism  322  has a slanted conveyor  324  extending from an end of the swing conveyor  292  in the pit  290  obliquely upwardly toward the scrap collecting mechanism  256 . The slanted conveyor  324  comprises an endless belt  328  circulatingly movably trained around pulleys  326   a ,  326   b , and a passage member  330  extending over the endless belt  328  and serving as a scrap feed path. A motor  334  is supported on a post  332  above an upper end of the slanted conveyor  324 . The motor  334  has a rotatable shaft operatively connected to the pulley  326   a  by a chain and sprocket mechanism  336 . 
     A plurality of magnets  338  are mounted at spaced intervals on an outer peripheral surface of the endless belt  328 . The magnets  338  are movable with the endless belt  328  obliquely upwardly along the lower surface of the passage member  330  closely thereto. The passage member  330  comprises an elongate plate of stainless steel (SUS), and extends above and along the endless belt  328  from the end of the swing conveyor  292  to the scrap collecting mechanism  256 . As shown in FIG. 21, the passage member  330  is of a substantially channel cross section and has a feed surface  330   a  along which scrap will be fed and a pair of guide surfaces  330   b ,  330   c  extending perpendicularly to respective opposite side edges of the feed surface  330   a . As shown in FIG. 20, a scraper blade  340  is positioned near the upper end of the passage member  330  for removing scrap from the passage member  330 . 
     The feed mechanism  322  operates as follows: The first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  are delivered from the swing conveyor  292  onto the passage member  330  of the slanted conveyor  324 . The endless belt  328  of the slanted conveyor  324  is circulatingly operated by the motor  334  through the chain and sprocket mechanism  336 , moving the magnets  338  with the endless belt  328  obliquely upwardly along the lower surface of the passage member  330  closely thereto. 
     Therefore, the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  supplied onto the passage member  330  are fed obliquely upwardly along the feed surface  330   a  while being magnetically attracted by the magnets  338 . At the upper end of the slanted conveyor  324 , the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  are caused by the scraper blade  340  to fall off the end of the passage member  330  into the chute  302  that is positioned therebelow. 
     Since the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  are fed along the feed surface  330   a  of the passage member  330 , they are prevented from being introduced into the endless belt  328 . The guide surfaces  330   b ,  330   b  on the opposite sides of the feed surface  330   a  are effective to prevent the first, second, and third scraps  230   a - 230   c  and the fourth, fifth, and sixth scraps  244   a - 244   c  from dropping off the side edges of the slanted conveyor  324 . 
     As described above, the machining apparatus for machining the elongate web-shaped workpiece according to the present invention machines the elongate web-shaped workpiece unreeled from the workpiece supply with the machining sections or stations to manufacture products, and automatically separates the products from scrap and feeds the products with the product feeder to the product collecting mechanism. Therefore, only desired products can automatically and efficiently be produced from the elongate web-shaped workpiece. 
     Furthermore, the scrap processing apparatus according to the present invention has the single feed mechanism for feeding first and second scraps from the first and second machining apparatus altogether to the scrap collecting mechanism. The first and second machining apparatus do not need to be combined with respective dedicated scrap processing apparatus. The entire facility of the scrap processing apparatus is thus relatively simple in structure and small in size, and can process the scraps 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.