CN109416328A - 包装体的图像检查系统 - Google Patents

包装体的图像检查系统 Download PDF

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Publication number
CN109416328A
CN109416328A CN201880002675.6A CN201880002675A CN109416328A CN 109416328 A CN109416328 A CN 109416328A CN 201880002675 A CN201880002675 A CN 201880002675A CN 109416328 A CN109416328 A CN 109416328A
Authority
CN
China
Prior art keywords
image data
package body
filling
packaging machine
determination unit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201880002675.6A
Other languages
English (en)
Inventor
二瀬克规
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
U Shin Ltd
Original Assignee
Yuhshin Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2017031176A external-priority patent/JP6172784B1/ja
Priority claimed from JP2017110039A external-priority patent/JP6229193B1/ja
Application filed by Yuhshin Co Ltd filed Critical Yuhshin Co Ltd
Publication of CN109416328A publication Critical patent/CN109416328A/zh
Pending legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/90—Investigating the presence of flaws or contamination in a container or its contents
    • G01N21/9081—Inspection especially designed for plastic containers, e.g. preforms
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/0002—Inspection of images, e.g. flaw detection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/032—Mechanical after-treatments
    • B29C66/0322—Post-pressing without reshaping, i.e. keeping the joint under pressure after joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/032—Mechanical after-treatments
    • B29C66/0326—Cutting, e.g. by using waterjets, or perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/345—Progressively making the joint, e.g. starting from the middle
    • B29C66/3452—Making complete joints by combining partial joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • B29C66/4312—Joining the articles to themselves for making flat seams in tubular or hollow articles, e.g. transversal seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7373—Joining soiled or oxidised materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B29C66/81465—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint one placed behind the other in a single row in the feed direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
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    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8351—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws
    • B29C66/83511—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums
    • B29C66/83513—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums cooperating jaws mounted on rollers, cylinders or drums and moving in a closed path
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明提供一种包装体的图像检查系统，能够自动地判别所制造出的包装体是否良好，并且能够自动地变更充填包装机的生产条件，所述包装体的图像检查系统具备充填包装机、图像数据判定系统、存储装置以及图像数据分析系统，其中，所述图像数据判定系统具备：摄像装置，其拍摄包装体；存储部，其存储用于判定包装体是否良好的判定条件；判定部，其判定包装体是否良好；以及图像数据发送部，其向存储装置发送由摄像装置拍摄得到的图像数据等，所述图像数据分析系统具备：图像数据获取部，其从存储装置获取被判定部判定为不良的图像数据等；运算部，其包括分析部和判定条件修正部，其中，所述分析部根据由图像数据获取部获取到的图像数据，来分析充填包装机的生产条件，所述判定条件修正部对所述判定部中的判定条件进行修正；以及发送部，其向充填包装机发送新的生产条件，并且向所述存储部发送新的所述判定条件。

Description

包装体的图像检查系统
技术领域
本发明涉及一种包装体的图像检查系统，该包装体是将食品饮料、调味品、化妆品、医药品等液状或粘稠状的被包装物充填到由塑料膜构成的包装袋内并进行包装而形成的。
背景技术
关于用于将液状或粘稠状的被包装物自动地充填到由塑料膜构成的包装袋内并进行包装的充填包装机，已知如专利文献1和专利文献2所记载的那样的自动充填机。
该自动充填机构成为：例如一边使由具备基膜层和密封层的层叠膜构成的长条的包装用膜沿其长边方向从上方向下方连续地行进，一边以使所述密封层相面对的方式将该包装用膜沿短边方向对折，将该重合的膜两侧缘彼此沿纵向连续地进行热封，来形成纵密封部，以将该膜形成为筒状，接着，在该筒状的包装用膜的成为底部侧的部位沿着该包装用膜的短边方向横向地进行热封，来形成横密封部，向该筒状的包装用膜内充填被包装物，并且一边将该被包装物挤出，一边在成为袋口侧的部位形成横密封部，由此连续地制造包装体。
专利文献1：日本特开平8-301237号公报
专利文献2：日本特开2006-248578号公报
专利文献3：日本特开2016-47738号公报
发明内容
发明要解决的问题
该自动充填机构成为，具有具备各种开关、触摸面板的操作面板，能够通过在该操作面板中按每个项目输入数值来设定与包装方式相应的生产条件(包装用膜的输送速度的设定、密封间距的设定、被包装物的充填量的设定或动作定时的设定、纵密封机构、横密封机构的密封压力的设定或动作定时的设定等生产条件等)。
然而，上述自动充填机的设定需要基于经验进行的精细的调整，因此用户不自行进行设定，例如当发生密封部不良等问题时，自动充填机的生产商的作业人员前往用户的所在地对自动充填机进行设定变更(调整)。因此，存在直至再开始运转为止花费时间这样的问题。
另外，存在以下情形：当生产条件(设定)不适当时，在纵密封部、横密封部产生皱褶、泡。即使这样的皱褶、泡小到数μm左右，但也有可能由于该泡连在一起或者多个泡、皱褶组合等而形成贯通孔或者在经过一段时间后成为贯通孔那样的伪贯通孔，从而被包装物在一日～数日后通过该贯通孔或伪贯通孔开始发生泄漏、即发生所谓的缓慢泄漏(延迟泄漏)。这样的数μm的泡、皱褶等难以通过目视来进行确认，因此以往将制造出的包装体暂时保管三天左右，根据实际有无漏液来判定包装体是否良好。
但是，在该方法中，存在需要确保用于保管大量的包装体的场所的问题点、无法在制造后立即出货的问题点、在发生了漏液的情况下污损周围的包装体的问题点等很多的问题点。而且，包装体大多以经由横密封部而多个连在一起的状态(连包状态)出货，在该情况下，即使在包装体间的横密封部内存在密封不良部分，由于在出货目的地逐包地进行切断之前不会产生漏液，因此无法在出货前探测该密封不良部分并判定缓慢泄漏的可能性。
此外，关于从包装体的缓慢泄漏，其大半是从横密封部以及横密封部与纵密封部交叉的位置发生的。作为其原因，能够例举以下原因：第一，当在如上述那样将长条的包装用膜沿短边方向折叠并对侧缘彼此进行纵密封来形成为筒状后将被包装物充填到该筒状的包装用膜内时，包装用膜由于被包装物的重量而变形，从而容易产生纵皱褶，特别是在如专利文献3的那样将包装体的长条的侧部密封部侧作为横密封部的情况下，所述皱褶的产生变得显著，通过在该状态下实施横密封，在横密封部以及横密封部与纵密封部交叉的位置产生贯通密封部的贯通皱褶，经由该贯通皱褶产生漏液。
另外，作为第二原因，能够例举通过利用一对横密封辊一边将液状的被包装物挤出一边进行热封的液中密封充填来形成横密封部。关于该液中密封充填，由于被包装物的温度、种类等不同而容易在热封时产生偏差，从而容易产生热封不良。
并且，在横密封部内不可避免地存在被包装物，因此容易有一部分滞留、残留并被夹在横密封部内。特别是在被包装物为将氮气等气体与液状物一同进行充填形成的气液混相流体的情况下，横密封部内夹有气体的可能性高，另外，被夹在横密封部内的液状物在被从由横密封辊产生的压力中释放出的同时膨胀(200～600倍)而起泡，当所述气泡、泡贯通横密封部或者多个泡以贯通横密封部的方式连续地形成时，成为密封不良而导致立即漏液，根据该气泡的状态或与皱褶的关系，还有可能发生缓慢泄漏。
而且，存在以下情况：在横密封部内产生的泡在紧挨着横密封辊之后的横密封部处于高温状态的期间保持处于起泡状态，但当在向下游侧移动的期间被冷却时，收缩并消失，因此即使存在导致立即漏液那样的大的泡，也无法发现该大的泡。
本发明的目的在于解决上述问题，提供一种能够自动地判别所制造出的包装体是否良好、并且能够自动地变更充填包装机的生产条件的包装体的图像检查系统。
用于解决问题的方案
为了解决上述目的而进行认真研究的结果，发明人们想到了以下所述的主旨结构所涉及的本发明。
即，本发明是一种包装体的图像检查系统，所述包装体由塑料膜构成，所述图像检查系统的特征在于，具备充填包装机、图像数据判定系统、存储装置以及图像数据分析系统，其中，所述图像数据判定系统包括：摄像装置，其拍摄利用所述充填包装机制造出的包装体；存储部，其存储用于判定所述包装体是否良好的判定条件；判定部，其根据由所述摄像装置拍摄得到的包装体的图像数据，来判定该包装体是否良好；以及图像数据发送部，其将所述图像数据和/或与该图像数据有关的信息同所述判定部的判定结果及所述充填包装机的生产条件一起经由通信单元发送到所述存储装置，所述图像数据分析系统包括：图像数据获取部，其从所述存储装置获取被所述判定部判定为不良的所述图像数据和/或与该图像数据有关的信息；运算部，其包括分析部和判定条件修正部，其中，所述分析部根据由所述图像数据获取部获取到的所述图像数据和/或与该图像数据有关的信息，基于所述存储装置中累积的过去的图像数据或与该图像数据有关的信息、以及与该图像数据或该信息相关联的所述充填包装机的生产条件，来分析所述不良的原因以及用于解决该不良的新的生产条件，所述判定条件修正部在根据由所述判定部判定为不良品的包装体的保管和观察的结果而判断为该判定部的判定不正确的情况下，对所述判定条件进行修正；以及发送部，其经由通信单元向所述充填包装机发送由所述分析部得到的所述新的生产条件，并且向所述存储部发送由所述判定条件修正部得到的新的判定条件。
此外，在本发明中，更优选的解决方案为，所述判定部具有分类部，该分类部将所述图像数据和/或与该图像数据有关的信息按规定的类别进行分类，所述图像数据发送部将属于各所述类别的图像数据和/或与该图像数据有关的信息的个数同所述充填包装机的现状的生产条件及所述判定部的所述判定结果相关联地发送到所述存储装置。
发明的效果
根据本发明的包装体的图像检查系统，自动地判别所制造出的包装体是否良好，并且自动地变更充填包装机的生产条件，因此能够缩短从伴随不良的发生而导致的操作停止起直至操作再开始为止的时间。
另外，根据本发明的图像检查系统，使用图像数据来判定所制造的包装体是否良好，因此还能够检测通过目视无法确认的那样的小的缺陷。特别是还能够检测通过以往的目视甄别无法确认的在热封部上产生的数μm左右的小的皱褶、泡，因此能够在紧挨着包装体制造之后判定该皱褶等是否成为缓慢泄漏的原因，从而能够进行不需要缓慢泄漏的探测所需的时间(待机时间)的在线的探测，因此能够削减漏液检查所需的时间、场所以及成本。
并且，根据本发明的图像检查系统，作为用于判定包装体是否良好的判定条件，能够利用将过去的图像数据、从该图像数据中提取出的特征数据根据缺陷部位和大小等以及包装体的生产条件(包装体的品种或间距、充填包装机的运转条件等)进行图案化所得到的判定条件。此外，判定条件不限定于图像数据、特征数据。
附图说明
图1是表示本发明的图像检查系统的一个实施方式的框图。
图2是表示充填包装机的结构的示意图。
图3是表示在判定部中被判定为“不良品”的图像数据(a)以及被判定为“良品”的图像数据(b)的一例的图。
图4的(a)是将图2的充填包装机的第一横密封辊部分放大表示的图，图4的(b)是将横密封部分放大表示的图。
图5是说明根据摄像图像与包装用膜的印刷相符合地变更曝光来制作合成图像的方法的图。
图6是表示本发明的图像检查系统的其它实施方式的框图。
具体实施方式
下面，参照附图来说明本发明所涉及的图像检查系统。
图1是本发明的一个实施方式所涉及的图像检查系统的框图。
如图1所示，本实施方式所涉及的图像检查系统1具备：充填包装机10，其用于制造作为检查对象的充填包装体；图像数据判定系统20，其根据利用充填包装机10制造的包装体的图像数据，来判定包装体是否良好；存储装置30，其累积从该充填包装系统10发送的图像数据等；以及图像数据分析系统40，其根据该存储装置30中累积的不良品的图像数据等，来分析其不良原因。所述充填包装机10、所述图像数据判定系统20、所述存储装置30以及图像数据分析系统40经由LAN、因特网等通信单元连接。
充填包装机10能够设为如专利文献1、2所记载的那样的立式充填包装机，除此以外，还能够设为卧式充填包装机、他列式充填包装机等各种充填包装机。下面，以图2所示的立式充填包装机为代表例来进行说明。充填包装机10一边使从膜辊R连续地被抽出并行进的一张长条的包装用膜F从上方向下方连续地行进，一边在包装用膜F的行进中通过导杆100进行引导并且将包装用膜F以其密封层彼此相面对的方式沿短边方向折叠，在图中使包装用膜F的位于左端部的其两侧端部彼此重合，利用由一对纵密封辊构成的纵密封机构101沿包装用膜F的长边方向(纵方向)对该重合的两侧端部彼此连续地进行加压和加热，来形成纵密封部102，由此将包装用膜F形成为筒状。接着，利用在上述一对纵密封辊之间自上而下贯通的充填嘴103，来将从未图示的罐经由未图示的泵和供给路径供给的被包装物M连续地、或每次以规定量间断地充填到形成为筒状的包装用膜F'的内侧，并且对形成为筒状的包装用膜F’以在其长边方向上隔开固定间隔的方式利用由一对横密封辊构成的第一横密封机构104全幅地进行加热并且进行加压，来使彼此熔接，从而间断地形成横密封部105。之后，利用第二横密封机构106再次按压横密封部105来使该密封可靠，由此多个包装体W以在包装用膜F的长边方向上相连的状态被连续地制造。此外，也可以如图所示的那样在第二横密封机构106的下游侧设置切断机构107，将包装体W每一袋或者每多袋地切断。
图像数据判定系统20由具备CPU和存储器等的计算机构成，该图像数据判定系统20具有：摄像装置21，其用于拍摄在上述充填包装机10中制造的包装体W的规定的检查部位；以及判定部22，其通过将由该摄像装置21拍摄得到的图像数据与存储部23中累积的作为判定包装体是否良好的基准的判定条件进行比较，来判断该图像数据中映出的包装体W是否良好。
摄像装置21是拍摄在充填包装机10中连续地制造的包装体W的装置，例如能够使用CCD摄像机、红外摄像机、CMOS摄像机等。摄像装置21只要能够检测在纵密封部102和横密封部105上产生的数μm左右的皱褶、瑕疵、泡等即可，不特别进行限定。
摄像装置21只要能够拍摄包装体W的规定的检查部位即可，可以设置于充填包装机10的任意的位置，另外，也可以设置多个摄像装置21，从而能够拍摄多个检查部位。
此外，包装体W容易由于纵密封部102及横密封部105的密封不良(皱褶、连续泡的产生)而产生漏液，因此优选的是，至少将该密封部102、105位置、特别是纵密封部102与横密封部105交叉的位置设为检查部位。另外，在包装体W具备日本特开2005-59958号公报所记载的那样的膜状的倒出嘴的情况下，优选将该倒出嘴的安装位置、外观设定为检查部位，从而能够检查该倒出嘴的安装位置的偏差、倒出嘴顶端的弯曲等。
判定部22具有如下的功能：将由摄像装置21获取到的图像数据与考虑从充填包装机10(数据输出部15)获取到的生产条件而被登记到图像数据判定系统20的存储部23中的判定条件进行比较，由此判定该图像数据中映出的包装体W是否良好。
作为判定条件，并不特别进行限定，例如能够使用基准图像数据、基准特征数据。
基准图像数据包括良品的基准图像和/或不良品的基准图像，作为良品的基准图像，包括完全不存在缺陷部位的图像，除此以外，还包括虽然存在缺陷部位但达不到产生不良的程度的图像。另一方面，不良品的基准图像是指在产生了与该图像内存在的皱褶、泡等缺陷的产生图案同样的图案的缺陷的情况下发生漏液等不良的可能性高的图像。
此外，可以将与良品的基准图像的比较及与不良品的基准图像的比较分两个阶段来进行，例如，在进行基于良品的基准图像的判定之后，针对被判定为“不良品”的包装体W进一步进行基于不良品的基准图像的判定，由此能够提高判定精度。
另外，基准特征数据是从过去拍摄得到的图像数据中按特征提取出成为漏液等不良的产生原因的皱褶、泡等缺陷部位并进行数据化得到的，例如，针对皱褶的个数、粗细、长度、位置以及泡的个数、大小、位置等各项目分别预先将产生不良的基准数据化并且累积在存储部23中。
在判定部22中进行判定时，从由摄像装置21拍摄得到的图像数据中提取特征数据(缺陷的种类、个数、位置等)，将该特征数据与存储部23中累积的基准特征数据进行比较，由此判定图像数据中映出的包装体W是否良好。
在判定部22中判定结果为“不良品”的情况下，如果从判定部22向充填包装机10的控制部12输出排除信号，来将被判定为不良品的包装体W从设置于充填包装机10的排出部13排出到其它线，则不存在怀疑是不良品的包装体W被出货的可能性。此外，优选针对包装体W预先在包装用膜F上印刷条形码、QR码(注册商标)等，如果通过该条形码等将图像数据与不良品的包装体W进行比对，则能够准确地从排出部13排出该包装体W。
在图3中示出在判定部22中被判定为“不良品”的图像数据(a)以及被判定为“良品”的图像数据(b)的一例。该图像数据是对包装体W的纵密封部102与横密封部105交叉的位置进行拍摄而得到的，在被判定为“不良品”的图像数据(a)中，在箭头所示的位置处产生了沿横密封部105的长边方向贯通的皱褶。
在此，将在判定部22中判定横密封部105的密封不良的方法作为一例来进行说明。
在图4的(a)中示出图2的充填包装机10的第一横密封辊104部分的放大侧视图。如图4的(a)所示，在第一横密封辊104的包装用膜F的行进方向下游侧设置有摄像装置21，该摄像装置21包括以与包装体W相面对的方式设置的红外摄像机21a、以及在隔着包装用膜F而与红外摄像机21a相向的位置处设置的红外线照射装置21b。作为红外摄像机21a，优选使用如下摄像机：搭载有CCD传感器、CMOS传感器等，对从由红外线LED等构成的红外线照射装置21b照射出的波长为700nm～1700nm的近红外线具有感光度。这是因为，当利用可见光摄像机拍摄包装用膜F时，可见光线在包装用膜F的表面发生反射，从而无法拍摄横密封部105内，与此相对，近红外线透过包装用膜F并在横密封部105内产生的泡、皱褶等非密封位置处发生反射，因此显现出线，从而能够清晰地拍摄缺陷像。
此外，优选将包括红外摄像机21a和红外线照射装置21b的摄像装置21设置为在如下位置拍摄如图4的(a)所示那样利用第一横密封辊104间断地形成的横密封部105，该位置为从第一横密封辊104、特别是利用第一横密封辊104形成的横热封位置(在一对第一横密封辊104的周向上等间隔地设置的热封杆104a彼此抵接的位置)起在包装用膜F的行进方向上相距长度L为30cm以内的位置，更优选为20cm以内的位置。
像这样，当在紧挨着第一横密封辊104之后、特别是在与第一横密封辊104相距30cm以内的位置处拍摄横密封部105时，横密封部105由于第一横密封辊104的加热而处于高温状态，因此能够对在横密封部105内产生的泡在保持起泡状态下进行拍摄。因此，能够根据摄像图像来检测横密封部105内的很多泡连在一起的状态、泡与皱褶连通的状态等，因此能够判定它们是否成为导致缓慢泄漏的密封不良部分。此外，在摄像位置变为从第一横密封辊104起向包装用膜F的行进方向下游侧分离超过30cm的位置的情况下，在横密封部105内产生的泡随着该横密封部105的冷却而收缩，特别是数μm左右的小的泡会完全消失，因此即使是会产生缓慢泄漏这样的密封不良部分，也无法根据摄像图像检测出来，有可能无法在紧挨着包装体W的制造之后探测缓慢泄漏。
另外，存在以下情况：在利用第一横密封辊104对包装用膜F加热时，纵密封部102与横密封部105一同被加热而再次熔融，在此时产生皱褶。在该情况下，如果利用红外摄像机21a拍摄与横热封位置相距30cm以内的位置，则也能够对横密封部105内产生的泡在保持起泡的状态下进行拍摄，因此能够判定该泡与在横密封部105同纵密封部102交叉的位置处产生的皱褶是否连通并成为密封不良部分。
关于由摄像装置21拍摄得到的图像(影像信号)，使用由计算机等构成的图像处理装置来提取横密封部105内的皱褶或气泡的相连、皱褶与气泡的组合等特征数据(例如皱褶的长度、位置、气泡的大小、位置、个数等)，在判定部22中将该特征数据与存储部23中累积的基准特征数据(例如基准图像数据、将过去产生的缺陷按种类、特征进行数据化所得到的数据)进行比较。
特别是如图4的(b)所示的那样，从处于被拍进所述摄像图像中的横密封部105的自被包装物的靠充填空间侧的密封边缘108起沿纵密封方向3.0mm以内的区域110(图4的(b)中用单点划线表示的区域，以下称作“判定区域110”。)的贯通孔(与充填空间相连的贯通孔)或者伪贯通孔(经过一段时间后与充填空间相连的贯通孔)提取特征数据，在判定部22中将该特征数据与存储部23中累积的基准特征数据进行比较，由此能够在紧挨着包装体W制造之后进行在从制造包装体W起经过一段时间后产生漏液的缓慢泄漏的判定。
这是因为，横密封部105如果以充填空间侧的密封边缘108在纵密封方向上为3.0mm、至少为1.0mm的长度的方式连续地形成为带状，则能够赋予足够的密封强度，也就是说，当在该判定区域110存在微细的泡、皱褶等密封不良部分时，横密封部105的剥离以该部分为起点在数小时～数日内逐渐加重，当在切断位置111处(横密封部105的长边方向中央位置)切断横密封部105时，从切断端面产生漏液(缓慢泄漏)。
在图4的(b)的情况下，非密封部分109a由于气泡的相连而形成，但由于该非密封部分109a位于判定区域110的区域外，因此被判定为不可能产生缓慢泄漏，与此相对，非密封部分109b位于判定区域110内的密封边缘108部分，因此被判定为有可能产生缓慢泄漏。
另外，在包装用膜F印刷有颜色、花纹、字符等情况下，例如当使红外摄像机21a的光圈值对准印刷部分时，没有印刷的部分变得过亮，相反地，当将红外摄像机21a的光圈值调整到没有印刷的部分时，印刷部分变得过暗，均无法拍出横密封部105整体。
因此，优选的是，设置曝光不同的多台红外摄像机21a，利用图像处理装置从由各个摄像机21a拍摄得到的多张摄像图像、或基于由红外摄像机21a拍摄得到的一张摄像图像调整清晰度和/或曝光所得到的多张图像中剪切出最合适的部分(横密封部105内部被清晰地拍出的部分)并进行合成(重构)。在该方法中，如图5所例示的那样，在区域A具有印刷、区域B由透明膜构成的情况下，基于由红外摄像机21a拍摄得到的一张摄像图像(a)使用图像处理装置分别制作使曝光对准区域A得到的图像(b)以及使曝光对准区域B得到的图像(c)，从图像(b)中剪切出区域A的部分，另一方面，从图像(c)中剪切出区域B的部分，将剪切出的区域A的部分与区域B的部分进行组合来形成合成图像(d)。由此，能够不被包装用膜F的印刷层妨碍地将横密封部105整体以一张图像清晰地拍出，因此能够通过与不具有印刷层的包装用膜F相同的方法来进行缓慢泄漏的判定。
如上述的那样，被判定部22进行判定的图像数据与该判定结果及充填包装机10的生产条件一同从图像数据发送部24发送到存储装置30并被累积。此外，在将基准特征数据用作判定条件的情况下，在判定部22中进行判定时，也可以将从图像数据中提取出的特征数据与图像数据一同从图像数据发送部24发送到存储装置30，或者用该特征数据代替图像数据从图像数据发送部24发送到存储装置30。下面，将图像数据以及从该图像数据中提取出的特征数据合称为“图像数据等”。
图像数据发送部24具有如下功能：将由摄像装置21拍摄得到的图像数据等与充填包装机10的现状的生产条件的信息及判定部22的判定结果相关联地经由作为通信单元的因特网发送到存储装置30。例如以每天约10万个的速度大量地生产包装体W，因此也可以设为每隔几分钟或几小时集中地进行发送。
存储装置30具有如下功能：累积由图像数据判定系统20获取到的图像数据等以及与该图像数据等相关联的生产条件、判定结果的信息等。该存储装置30保存被发送来的大量的图像数据等，因此优选的是，例如将该大量的图像数据等与缺陷部位的图案及生产条件(例如塑料膜的品种、被包装物的种类、充填量、间距等)相关联地分为多个目录、文件夹来进行保存。
特别是存储装置30中累积的图像数据等被用作在后述的运算部42中分析不良品的产生原因时的累积信息数据，因此优选在向存储装置30累积图像数据等时，基于缺陷的形态和生产条件等细小地进行分类并图案化，由此，使得缺陷的形态与生产条件之间的关系变得明确，后述的运算部42能够迅速且高精度地进行分析作业。
针对存储装置30中累积的图像数据等中的被判定部22判定为不良品的图像数据等，在图像数据分析系统40中研究缺陷产生的原因和对策。
图像数据分析系统40由具备CPU、存储器等的计算机构成，具备图像数据获取部41和运算部42，该图像数据获取部41具有如下功能：从被新登记到存储装置30中的图像数据等中获取被判定部22判断为“不良品”的图像数据等。另一方面，关于被判断为“良品”的图像数据等，能够作为溯源(日文：トレーサビリティ)(生产履历)被使用于包装体的生产管理。
运算部42具有分析部43，该分析部43通过将从图像数据获取部41获取到的“不良品”的图像数据等与存储装置30中累积的累积信息数据(过去的图像数据、特征数据)进行比较，来分析缺陷产生的原因。具体地说，分析部43例如使被判定为不良品的图像数据等与存储装置30中大量地累积的过去的信息(图像数据、特征数据、生产条件等)进行匹配来确定原因。另外，分析部43能够基于过去的图像数据等及与该过去的图像数据等相关联的生产条件等，来计算用于根据分析结果来消除缺陷的产生的充填包装机10的新的生产条件(例如包装用膜F的张力、纵密封机构101的温度和速度、第一横密封机构104的温度和速度、生产速度的升降等)。
由分析部43计算出的新的生产条件经由发送部45被输入到充填包装机10的控制部12，来自动地设定变更该充填包装机10的生产条件(例如包装用膜F的张力的强弱、纵密封机构101的温度和速度的变更、第一横密封机构104的温度和速度的变更、生产速度的升降等)。因此，能够缩短从伴随不良的产生而导致的操作停止起直至操作再开始为止的时间，或者不使操作停止而能够解决不良。
另外，针对被判定部22判定为不良品并经由排出部13从制造线去除的包装体W(伪不良品)，进行数日的保管、观察来确认漏液等不良的发生。其结果被输入到判定条件修正部44。在尽管被判定部22判定为不良品但没有发生漏液的情况下，判定条件修正部44向发送部45输出用于变更作为判定条件的基准图像数据、基准特征数据的指示(用于将成为误判定的基准的图像、特征数据进行删除或修正的指示等)。发送部45经由作为通信单元的因特网向图像数据判定系统20的存储部23发送该指示，来变更所累积的基准图像数据、基准特征数据(将成为误判定的基准的图像、特征数据等进行删除或修正)。此外，每当在判定部22中发生误判定时就反复进行该处理，由此判定部22的判定精度提高，能够减少尽管为良品但被作为不良品拾取的频度。
接着，参照图6来说明本发明的图像检查系统的其它实施方式。在本实施方式中，判定部22具有将图像数据等基于从该图像数据中提取出的信息(例如皱褶、泡的位置、大小、个数等)按规定的类别进行分类的分类部25，来代替图像数据发送部24将由摄像装置21拍摄得到的图像数据等保持原样地发送到存储装置30的方式。图像数据发送部24构成为将各类别的分类条件、属于各类别的图像数据的个数、充填包装机10的现状的生产条件以及判定部22的判定结果等分别相关联地发送到存储装置30。如果像这样构成，则相比于将由摄像装置21拍摄到的图像数据等保持原样地发送到存储装置30的情况而言，能够使信息量显著减少，因此能够减少通信负荷，并且能够进行更接近实时的发送。
附图标记说明
10：充填包装机；12：控制部；13：排出部；15：数据输出部；20：图像数据判定系统；21：摄像装置；21a：红外摄像机；21b：红外线照射装置；22：判定部；23：存储部；24：图像数据发送部；25：分类部；30：存储装置；40：图像数据分析系统；41：图像数据获取部；42：运算部；43：分析部；44：判定条件修正部；45：发送部；100：导杆；101：纵密封机构；102：纵密封部；103：充填嘴；104：第一横密封机构；105：横密封部；106：第二横密封机构；107：切断机构；108：密封边缘；109a、109b：非密封部；110：判定区域；111：切断位置。

Claims (2)

1.一种包装体的图像检查系统，所述包装体由塑料膜构成，所述图像检查系统的特征在于，
具备充填包装机、图像数据判定系统、存储装置以及图像数据分析系统，
其中，所述图像数据判定系统包括：
摄像装置，其拍摄利用所述充填包装机制造出的包装体；
存储部，其存储用于判定所述包装体是否良好的判定条件；
判定部，其根据由所述摄像装置拍摄得到的包装体的图像数据，来判定该包装体是否良好；以及
图像数据发送部，其将所述图像数据和/或与该图像数据有关的信息同所述判定部的判定结果以及所述充填包装机的生产条件一起经由通信单元发送到所述存储装置，
所述图像数据分析系统包括：
图像数据获取部，其从所述存储装置获取被所述判定部判定为不良的所述图像数据和/或与该图像数据有关的信息；
运算部，其包括分析部和判定条件修正部，其中，所述分析部根据由所述图像数据获取部获取到的所述图像数据和/或与该图像数据有关的信息，基于所述存储装置中累积的过去的图像数据或与该图像数据有关的信息、以及与该图像数据或该信息相关联的所述充填包装机的生产条件，来分析所述不良的原因以及用于解决该不良的新的生产条件，所述判定条件修正部在根据由所述判定部判定为不良品的包装体的保管和观察的结果而判断为该判定部的判定不正确的情况下，对所述判定条件进行修正；以及
发送部，其经由通信单元向所述充填包装机发送由所述分析部得到的所述新的生产条件，并且向所述存储部发送由所述判定条件修正部得到的新的判定条件。
2.根据权利要求1所述的包装体的图像检查系统，其特征在于，
所述判定部具有分类部，该分类部将所述图像数据和/或与该图像数据有关的信息按规定的类别，所述图像数据发送部构成为，将属于各所述类别的图像数据和/或与该图像数据有关的信息的个数同所述充填包装机的现状的生产条件及所述判定部的所述判定结果相关联地发送到所述存储装置。
CN201880002675.6A 2017-02-22 2018-02-14 包装体的图像检查系统 Pending CN109416328A (zh)

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