JP5993358B2 - Inspection device and PTP packaging machine - Google Patents

Description

  The present invention belongs to a technical field including an inspection apparatus used in manufacturing a PTP sheet and a PTP packaging machine provided with the inspection apparatus.

  The PTP sheet is composed of a container film in which a pocket portion filled with contents such as tablets is formed, and a cover film that is attached to the container film so as to seal the opening side of the pocket portion. .

  In manufacturing the PTP sheet, inspections regarding abnormal appearance of the tablet and the sheet portion such as dirt and hair adhesion are performed.

  In general, in the appearance inspection of a PTP sheet, the illumination device irradiates the PTP sheet with light, and the PTP sheet irradiated with the light is imaged with an imaging device. And based on the imaged image data, tablet abnormality and sheet abnormality are detected.

  Conventionally, a CCD (Charge Coupled Devices) area sensor is known as an image sensor mounted on an image pickup apparatus. The CCD area sensor has a configuration with less variation in gain between pixels than a CMOS (Complementary Metal Oxide Semiconductor) area sensor having an amplifier for each pixel.

  For example, an interline transfer type CCD area sensor is two-dimensionally arranged in a matrix, and converts a plurality of light receiving portions (pixels) that store incident light into charges corresponding to the amount of light, and the light receiving portions stored therein. A plurality of vertical transfer units that transfer charges in the vertical direction, a horizontal transfer unit that transfers charges transferred from the vertical transfer unit in the horizontal direction, and a charge that is transferred from the horizontal transfer unit is converted into a voltage and amplified. Output amplifier.

  Usually, the appearance inspection of a PTP sheet is performed by imaging a container film or the like being transported after the contents such as tablets are filled. Therefore, the performance of the imaging device of the imaging device is required to be high speed and high resolution in addition to the stable gain between pixels.

  In recent years, a CCD area sensor that divides an imaging region into two left and right regions and outputs from the two regions in parallel from different channels may be used in order to cope with this increase in imaging speed. For example, see Patent Document 1).

JP-A-3-224371

  However, in a CCD area sensor having two output channels, an output amplifier is provided for each channel. Therefore, an image output from each channel due to variations in the characteristics of each amplifier, such as the gain of each amplifier not matching. There is a possibility that a luminance image composed of signals has a luminance difference between the left and right sides of the central portion. If such a problem occurs, the inspection accuracy may be significantly reduced.

  For example, when the tablet 100 shown in FIG. 12 (a) is imaged by a CCD area sensor having two output channels on the left and right sides, as shown in FIG. 12 (b), it is composed of image signals output from each channel. In the luminance image 101, there is a risk that a luminance difference occurs between the left and right sides of the central portion.

  Further, when a differentiation process or the like is performed on the luminance image 101 (see FIG. 12B) in order to detect the linear foreign matter 102 such as hair (see FIG. 12A) attached to the tablet 100, the differentiation is performed. In the image 103 (see FIG. 12C), a vertical line 105 appears at the center of the image where the luminance difference occurs. Of course, even when the linear foreign substance 102 does not adhere to the tablet 100, the vertical line 105 appears.

  As a result, the vertical line 105 and the linear foreign object 102 cannot be distinguished, and the linear foreign object 102 may not be detected. Conversely, even when the linear foreign matter 102 is not attached to the tablet 100, the vertical line 105 may be erroneously detected as the linear foreign matter 102.

  Even if the output levels of the two output channels are corrected, the output level of each channel changes sequentially with time and temperature change, and it is difficult to always match the two.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an inspection apparatus and a PTP packaging machine that can improve inspection efficiency and suppress a decrease in inspection accuracy when inspecting a PTP sheet. There is to do.

  Hereinafter, each means suitable for solving the above-described problem will be described separately. In addition, the effect specific to the means to respond | corresponds as needed is added.

Means 1. An inspection apparatus used in the manufacture of a PTP sheet in which contents are stored in a pocket portion formed in a belt-shaped container film to be transported, and a cover film is attached so as to close the pocket portion,
Irradiating means for irradiating the container film containing the contents with predetermined light;
Imaging means having an imaging element capable of imaging the contents irradiated with the light and the container film;
An image processing device for processing an image signal output from the imaging means,
The image sensor is
A CCD area sensor in which an imaging region is divided into a plurality of regions and outputs from the divided regions are performed in parallel from different channels,
The imaging means is arranged so that a position corresponding to a boundary portion of a plurality of divided areas of the imaging area is a position that does not overlap a predetermined inspection target area on an image captured by the imaging element. Inspection device characterized by

  According to the means 1, in the manufacturing process of the PTP sheet, for example, after contents such as tablets are accommodated in the pockets formed in the belt-like container film to be conveyed, the irradiation of the inspection apparatus is performed on the container film. Light is emitted from the means, and the contents and container film irradiated with the light are imaged by the imaging means. In the image processing apparatus, various inspections are performed based on the image acquired from the imaging unit.

  In this means, a CCD area sensor that divides an imaging region into a plurality of regions and outputs from the divided regions in parallel from different channels is used as the imaging device. As a result, high-speed continuous shooting is possible, and inspection efficiency can be improved. This is particularly effective in a high-resolution CCD area sensor having a large number of pixels in both the horizontal and vertical directions.

  In general, when a PTP sheet is inspected, various inspections are performed after an inspection target area is set in accordance with an inspection target such as a tablet or a sheet portion in order to perform an appropriate inspection. For example, when inspecting appearance defects of contents such as tablets, the pocket area of the PTP sheet is set as the inspection target area. On the other hand, when inspecting the appearance defect of the sheet portion, the sheet portion region excluding the pocket portion region of the PTP sheet is set as the inspection target region.

  Then, in this means, the image pickup means is arranged so that a position corresponding to a boundary portion of the plurality of divided areas of the image pickup area on the image picked up by the image pickup element is a position that does not overlap a predetermined inspection target area. Is arranged. For example, when the pocket area is set as the inspection target area, the position corresponding to the boundary between the plurality of divided areas of the imaging area is set as the sheet area.

  As a result, the output level of each channel of the CCD area sensor does not match, and a luminance difference occurs at a position corresponding to the boundary between the plurality of divided areas of the imaging area on the image captured by the imaging device. Even if it has, it can test | inspect appropriately about the area | region to be examined, without receiving the influence. As a result, it is possible to suppress a decrease in inspection accuracy while improving inspection efficiency.

Mean 2. Display means capable of displaying an image picked up by the image pickup means and a line indicating positions corresponding to boundaries of a plurality of areas divided in the image pickup area;
The inspection apparatus according to claim 1, further comprising a position adjustment unit capable of adjusting a position of the imaging unit.

  According to the means 2, the operator can align the imaging means while looking at the display means. For example, by looking at the image displayed on the display means, the position adjustment is performed so that the line indicating the position corresponding to the boundary portion of the imaging region does not overlap the inspection target region while determining the inspection target region and the non-inspection target region The position of the imaging means is adjusted by the means.

  As a result, the alignment operation of the imaging unit can be performed more easily and more easily, and the work efficiency can be improved. Furthermore, since the imaging unit can be aligned at a more appropriate position, further improvement in inspection accuracy can be achieved.

Means 3. The image processing apparatus includes:
Differential processing means for performing differential processing on the image captured by the imaging means;
The inspection apparatus according to means 1 or 2, further comprising a foreign matter detection means capable of detecting a foreign matter existing in the inspection target region based on the differential image subjected to the differentiation process.

  According to the said means 3, it becomes easy to detect linear foreign materials, such as hair and fiber waste, by performing a differentiation process.

  In the case where differential processing is performed as in this means, problems such as those exemplified in the above “problem to be solved by the invention” are likely to occur. That is, under the configuration of this means, the effect of the means 1 is more effective.

  Means 4. A PTP packaging machine comprising the inspection device according to any one of means 1 to 3.

  By providing the inspection apparatus in the PTP packaging machine as in the above means 4, there is a merit that defective products can be efficiently excluded in the manufacturing process of the PTP sheet.

In general, the PTP packaging machine includes a pocket portion forming means for forming a pocket portion for a container film conveyed in a strip shape, a filling means for filling the pocket portion with contents, and the pocket portion so as to close the pocket portion. Attachment means for attaching a belt-like cover film to the container film, and sheet punching means for punching the belt-like PTP film with the cover film attached to the container film in units of PTP sheets. In addition, the PTP packaging machine includes a discharge unit that discharges the PTP sheet that has been determined to be defective by the inspection apparatus.
Means 5. It is an inspection method used in manufacturing a PTP sheet in which contents are stored in a pocket portion formed in a belt-shaped container film to be conveyed, and a cover film is attached so as to close the pocket portion,
Irradiating the container film containing the contents with predetermined light using an irradiation means,
The contents irradiated with the light and the container film are imaged using an imaging means having an imaging element,
An image signal output from the imaging means is processed using an image processing device,
The image sensor is
A CCD area sensor in which an imaging region is divided into a plurality of regions and outputs from the divided regions are performed in parallel from different channels,
The imaging means is arranged so that a position corresponding to a boundary portion of the plurality of divided areas of the imaging area is a position that does not overlap a predetermined inspection target area on an image captured by the imaging element. Inspection method characterized by
Means 6. A method for producing a PTP sheet, comprising the inspection method according to means 5.

(A) is a perspective view which shows a PTP sheet, (b) is a perspective view which shows a PTP film. It is a partial expanded sectional view of the pocket part of a PTP sheet. It is a schematic diagram which shows schematic structure of a PTP packaging machine. It is a block diagram which shows the electric constitution of a test | inspection apparatus. It is a schematic diagram which shows schematic structure of a CCD area sensor. It is a schematic diagram which shows schematic structure of a camera position adjustment mechanism. It is a flowchart which shows a camera position setting routine. It is a flowchart which shows a test | inspection routine. It is a schematic diagram which shows an example of the display screen of the monitor at the time of camera position setting, Comprising: (a) is a figure which shows the state in which the center reference line overlapped with the pocket part area | region, (b) is a figure which shows a pocket part area | region. It is a figure which shows the state which does not overlap with a center reference line. It is a figure explaining the test | inspection procedure by a test | inspection apparatus, Comprising: (a) is a schematic diagram which shows the tablet used as test object, (b) is a schematic diagram which shows the brightness | luminance image which imaged (a), (c ) Is a schematic diagram showing a differential image obtained by differentiating (b). It is a schematic diagram which shows schematic structure of the CCD area sensor which concerns on another embodiment. It is a figure explaining the test | inspection procedure by the conventional test | inspection apparatus, Comprising: (a) is a schematic diagram which shows the tablet used as test object, (b) is a schematic diagram which shows the brightness | luminance image which imaged (a), (C) is a schematic diagram showing a differential image obtained by differentiating (b).

  Hereinafter, an embodiment will be described with reference to the drawings. First, the configuration of the PTP sheet to be inspected will be described in detail.

  As shown in FIGS. 1 and 2, the PTP sheet 1 has a container film 3 having a plurality of pocket portions 2 and a cover film 4 attached to the container film 3 so as to close the pocket portions 2. ing. Each pocket 2 stores one tablet 5 as a content.

  The container film 3 in the present embodiment is made of a transparent thermoplastic resin material such as PP (polypropylene) or PVC (polyvinyl chloride), and has translucency. On the other hand, the cover film 4 is made of aluminum.

  The PTP sheet 1 [see FIG. 1A] is formed by punching a belt-like PTP film 6 [see FIG. 1B] formed from the belt-like container film 3 and the belt-like cover film 4 into a sheet shape. Manufactured.

  Next, a schematic configuration of the PTP packaging machine 10 that manufactures the PTP sheet 1 will be described with reference to FIG.

  As shown in FIG. 3, on the uppermost stream side of the PTP packaging machine 10, the raw material of the strip-shaped container film 3 is wound in a roll shape. The drawer end side of the container film 3 wound in a roll shape is guided by a guide roll 13. The container film 3 is hooked on the intermittent feed roll 14 on the downstream side of the guide roll 13. The intermittent feed roll 14 is connected to a motor that rotates intermittently and transports the container film 3 intermittently.

  Between the guide roll 13 and the intermittent feed roll 14, a heating device 15 and a pocket portion forming device 16 are sequentially arranged along the conveyance path of the container film 3. Then, in a state where the container film 3 is heated by the heating device 15 and the container film 3 becomes relatively flexible, the pocket portion forming device 16 forms a plurality of pocket portions 2 at predetermined positions of the container film 3. The heating device 15 and the pocket portion forming device 16 constitute the pocket portion forming means in this embodiment. The pocket portion 2 is formed during an interval between the container film 3 transport operations by the intermittent feed roll 14.

  The container film 3 sent out from the intermittent feed roll 14 is hung in the order of the tension roll 18, the guide roll 19, and the film receiving roll 20. Since the film receiving roll 20 is connected to a motor that rotates at a constant speed, the container film 3 is transported continuously and at a constant speed. The tension roll 18 is in a state in which the container film 3 is pulled to the side where the container film 3 is tensioned by an elastic force, and prevents the container film 3 from being bent due to the difference in the transport operation between the intermittent feed roll 14 and the film receiving roll 20. The container film 3 is always kept in a tension state.

  A tablet filling device 21 is disposed between the guide roll 19 and the film receiving roll 20 along the conveyance path of the container film 3. The tablet filling device 21 has a function as a filling means for automatically filling the tablet 5 in the pocket portion 2. The tablet filling device 21 is configured to drop the tablets 5 by opening the shutter at predetermined intervals in synchronization with the transport operation of the container film 3 by the film receiving roll 20, and each pocket portion is accompanied by the shutter opening operation. 2 is filled with tablets 5.

  An inspection device 22 is disposed between the tablet filling device 21 and the film receiving roll 20 along the conveyance path of the container film 3. The inspection device 22 is a reflected light type inspection device, and is mainly for inspecting the appearance defect of the tablet 5. For example, the presence / absence of a tablet 5, cracks, chipping, dirt or foreign matter adhering to the tablet 5 are detected.

  On the other hand, the original film of the cover film 4 formed in a band shape is wound in a roll shape on the most upstream side.

  The drawn end of the cover film 4 wound in a roll shape is guided by the guide roll 24 and guided toward the heating roll 25. The heating roll 25 can be pressed against the film receiving roll 20, and the container film 3 and the cover film 4 are fed between the rolls 20 and 25. And the container film 3 and the cover film 4 pass between both the rolls 20 and 25 in a heating-pressing state, the cover film 4 is stuck to the container film 3, and the pocket part 2 is block | closed with the cover film 4. . Thereby, the PTP film 6 as a strip | belt-shaped body with which the tablet 5 was filled in each pocket part 2 is manufactured. On the surface of the heating roll 25, fine mesh-like ridges for sealing are formed, and a strong seal is realized by strongly pressing them. The film receiving roll 20 and the heating roll 25 constitute the attachment means in this embodiment.

  The PTP film 6 sent out from the film receiving roll 20 is hung in the order of the tension roll 27 and the intermittent feed roll 28. Since the intermittent feed roll 28 is connected to a motor that rotates intermittently, the PTP film 6 is intermittently conveyed. The tension roll 27 is in a state in which the PTP film 6 is pulled toward the side to be tensioned by the elastic force, and prevents the PTP film 6 from being bent due to the difference in the transport operation between the film receiving roll 20 and the intermittent feed roll 28. The PTP film 6 is always kept in tension.

  The PTP film 6 sent out from the intermittent feed roll 28 is hooked in the order of the tension roll 31 and the intermittent feed roll 32. Since the intermittent feed roll 32 is connected to an intermittently rotating motor, the PTP film 6 is intermittently conveyed. The tension roll 31 is in a state in which the PTP film 6 is pulled toward the side to be tensioned by an elastic force, and prevents the PTP film 6 from being bent between the intermittent feed rolls 28 and 32.

  Between the intermittent feed roll 28 and the tension roll 31, a slit forming device 33 and a marking device 34 are sequentially arranged along the transport path of the PTP film 6. The slit forming device 33 has a function of forming a slit for separation at a predetermined position of the PTP film 6. The marking device 34 has a function of marking a predetermined position (for example, a tag portion) of the PTP film 6.

  The PTP film 6 sent out from the intermittent feed roll 32 is wound on the downstream side in the order of the tension roll 35 and the continuous feed roll 36. A sheet punching device 37 is disposed between the intermittent feed roll 32 and the tension roll 35 along the transport path of the PTP film 6. The sheet punching device 37 has a function as a sheet punching unit that punches the outer edge of the PTP film 6 in units of one PTP sheet.

  The PTP sheet 1 punched by the sheet punching device 37 is transported by the take-out conveyor 39 and temporarily stored in the finished product hopper 40. When the inspection device 22 determines that the product is defective, the PTP sheet 1 determined to be defective is separately discharged by a defective sheet discharge mechanism (not shown) as discharge means.

  A cutting device 41 is disposed on the downstream side of the continuous feed roll 36. Then, the unnecessary film portion 42 constituting the remaining material portion (scrap portion) remaining in a strip shape after being punched by the sheet punching device 37 is guided to the tension roll 35 and the continuous feed roll 36 and then guided to the cutting device 41. It is burned. The continuous feed roll 36 is in pressure contact with a driven roll, and performs a conveying operation while sandwiching the unnecessary film portion 42. The cutting device 41 has a function of cutting the unnecessary film portion 42 into a predetermined size and scrapping. The scrap is stored in the scrap hopper 43 and then disposed of separately.

  The rolls 14, 20, 28, 31, 32 and the like have a positional relationship in which the roll surface and the pocket portion 2 face each other, but the pocket portion 2 is formed on the surface of the intermittent feed roll 14 or the like. Since the recessed part accommodated is formed, the pocket part 2 is not crushed. Further, the feeding operation is performed while the pocket portion 2 is accommodated in each recess such as the intermittent feeding roll 14, so that the intermittent feeding operation and the continuous feeding operation are reliably performed.

  Although the outline of the PTP packaging machine 10 is as described above, the configuration of the inspection apparatus 22 will be described in more detail below with reference to the drawings. FIG. 4 is a block diagram showing an electrical configuration of the inspection apparatus 22.

  As shown in FIG. 4, the inspection apparatus 22 includes an illumination device 52 as an irradiating means, a camera 53 as an imaging means, an image processing device 54, a monitor 55 as a display means, a keyboard 56 as an input means, and a camera 53. And a camera position adjusting mechanism 57 as position adjusting means for adjusting the position of the camera.

  The lighting device 52 and the camera 53 are arranged on the opening side of the pocket portion 2 of the container film 3. The light emitted from the illumination device 52 illuminates the tablet 5 and the like, and the light reflected from the tablet 5 and the like is two-dimensionally imaged by the camera 53. In the present embodiment, infrared light is emitted from the illumination device 52. According to the infrared light, an image in which the brightness of the tablet 5 itself is higher than that of the foreign matter can be obtained regardless of the color of the tablet 5.

  In the present embodiment, an interline transfer type CCD area sensor 53a that is sensitive to at least infrared light is employed as the image sensor of the camera 53 (see FIG. 5).

  As shown in FIG. 5, the CCD area sensor 53 a is a plurality of light receiving units that are two-dimensionally arranged in a matrix and that are formed by photoelectric conversion elements (for example, photodiodes) that convert incident light into charges corresponding to the amount of light. (Pixels) 81 are provided corresponding to each vertical column of the light receiving unit 81, and the charges accumulated in the light receiving units 81 of the vertical column are sequentially transferred by one row (one pixel) in the vertical direction. A plurality of vertical transfer units (vertical CCD shift registers) 82, a horizontal transfer unit (horizontal CCD shift register) 83 that sequentially transfers charges for one row transferred from the vertical transfer unit 82 in the horizontal direction, and the horizontal An output amplifier 85 that converts the electric charge transferred from the transfer unit 83 into a voltage, amplifies it, and outputs it is provided.

  In the present embodiment, the vertical direction of the CCD area sensor 53a is along the X-axis direction that is the film transport direction of the container film 3, and the horizontal direction is along the Y-axis direction that is the film width direction of the container film 3. In addition, a camera 53 is arranged.

  Further, as shown in FIG. 5, the CCD area sensor 53a according to the present embodiment has its imaging area 88 for one screen divided into two in the horizontal direction with the optical axis of the camera 53 as the center. The output from the area is performed in parallel from two different channels.

  More specifically, the electric charge read from the light receiving unit 81 included in the left imaging region 88A located on the left side in FIG. 5 is output from the left output amplifier 85A via the left horizontal transfer unit 83A. On the other hand, the electric charges read from the light receiving unit 81 included in the right imaging region 88B located on the right side in FIG. 5 are output from the right output amplifier 85B via the right horizontal transfer unit 83B.

  The image signals (image data) output from the output amplifiers 85A and 85B are combined as image signals (image data) for one screen imaged by the imaging area 88 via a circuit (not shown). At the same time, after being converted into a digital signal, it is output from the camera 53 to the image processing device 54.

  Next, the configuration of the camera position adjusting mechanism 57 will be described in more detail with reference to FIG. The camera position adjusting mechanism 57 includes a Z-axis moving mechanism 72 for sliding the camera 53 along the Z-axis direction, which is the normal direction of the container film 3, and the Z-axis moving mechanism 72 (camera 53). And a Y-axis moving mechanism 73 for sliding along the Y-axis direction (the direction perpendicular to the Z-axis direction and the direction perpendicular to the X-axis direction, which is the film transport direction), which is the film width direction 3. .

  Then, the operator can operate the keyboard 56 and the like to operate the Z-axis moving mechanism 72 and the Y-axis moving mechanism 73, thereby adjusting the imaging position and imaging range of the camera 53.

  As shown in FIG. 4, the image processing apparatus 54 includes an image memory 61 corresponding to the camera 53, a masking means 62, a binarizing means 63, a setting data memory 64, an inspection result and statistical data memory 65, and a camera timing control means 66. The differential processing means 67, the CPU and the input / output interface 68, and the like, can perform image data processing, appearance defect determination (determination of tablet defect and sheet defect), and the like as described later.

  The image memory 61 is a luminance image picked up by the camera 53, a masked image after masking processing by the masking means 62, a binarized image binarized by the binarizing means 63, and a differential image. This is for storing a differential image after differential processing by the processing means 67.

  The CPU and input / output interface 68 executes various processing programs while using the stored contents of the setting data memory 64, and sends various control signals to the PTP packaging machine 10 or various signals such as operation signals from the PTP packaging machine 10. Is for sending and receiving. Thereby, for example, the defective sheet discharge mechanism of the PTP packaging machine 10 can be controlled.

  The CPU and input / output interface 68 also has a function of sending display data to the monitor 55. With this function, various images, defect inspection results, and the like can be displayed on the monitor 55. Further, the CPU and input / output interface 68 has a function of inputting data from the keyboard 56.

  The setting data memory 64 stores, for example, determination reference values relating to appearance defect inspection, positional relationship data between the container film 3 and the camera 53, and shapes and dimensions of the PTP sheet 1, the pocket portion 2, and the tablet 5. is there.

  The inspection result and statistical data memory 65 stores data such as coordinates related to various images, inspection result data, statistical data obtained by probabilistically processing the inspection result data, and the like. These inspection result data and statistical data can be appropriately displayed on the monitor 55 based on the control of the CPU and the input / output interface 68. Further, the CPU and the input / output interface 68 can send a control signal to the PTP packaging machine 10 based on these inspection result data and statistical data.

  The camera timing control unit 66 controls the timing at which image data captured by the camera 53 is taken into the image memory 61. Such timing is controlled based on a signal from an encoder (not shown) provided in the PTP packaging machine 10, and every time the container film 3 is fed by a predetermined amount, imaging is performed in units of sheets by the camera 53 (for example, PTP sheets to be punched). .

  Next, the procedure of the appearance defect inspection performed by the inspection device 22 will be described. First, the “camera position setting routine” performed prior to the appearance defect inspection will be described in detail with reference to the flowchart of FIG.

  First, with the conveyance of the container film 3 stopped, the container film 3 is imaged (step S101), and the captured image is displayed on the monitor 55 (step S102).

  At the same time, on the display screen 55a of the monitor 55, as shown in FIGS. 9A and 9B, the center reference line R dividing the display screen 55a into the left and right is the screen vertical direction (the X axis that is the film transport direction). Direction).

  The center reference line R is a line indicating the position corresponding to the boundary between the left imaging area 88A and the right imaging area 88B obtained by dividing the imaging area 88 in two, and the position of the center (optical axis) of the camera 53 in the Y-axis direction. It is.

  Next, the position of the camera 53 is adjusted based on the image of the container film 3 and the center reference line R displayed on the display screen 55a of the monitor 55 (step S103). More specifically, while confirming the image of the container film 3 and the center reference line R displayed on the display screen 55a, the camera position adjustment mechanism 57 is operated by operating the keyboard 56 and the like to adjust the position of the camera 53.

  Here, in the inspection device 22 for inspecting the appearance defect of the tablet 5, the inspection target region is set to the pocket region 90a, so that the pocket region 90a does not overlap the center reference line R. Therefore, if the central reference line R is overlapped with the pocket area 90a (see FIG. 9A), the camera 53 is moved to the sheet area 90b along the Y-axis direction, The partial area 90a is prevented from overlapping the center reference line R [see FIG. 9B].

  When the position adjustment of the camera 53 is finished, the position of the camera 53 is fixed and the camera position setting routine is finished.

  Next, the “inspection routine” relating to the appearance defect inspection of the tablet 5 performed by the inspection device 22, mainly the detection of foreign matter or the like adhering to the tablet 5, will be described in detail with reference to the flowchart of FIG. 8.

  First, the tablet 5 to be inspected is irradiated with infrared light from the illumination device 52 to the container film 3 filled in the pocket portion 2, and the tablet 5 and the container film 3 irradiated with the infrared light are irradiated by the camera 53. Imaging is performed (step S201: imaging processing). Thereby, the luminance image data of the container film 3 filled with the tablets 5 is acquired.

  When the luminance image data is acquired, differentiation processing by the differentiation processing means 67 is performed on the luminance image data (step S202). Thereby, differential image data in which the contour of a foreign substance or the like is emphasized is acquired. By performing the differential processing, it becomes easy to detect linear foreign matters such as hair and fiber waste.

  When the differential image data is acquired, binarization processing by the binarization means 63 is performed on the differential image data (step S203). Thereby, the binarized image data in which the part where the foreign substance exists is “0 (dark)” and the normal part excluding this part is “1 (bright)” is acquired.

  When the binarized image data is acquired, a block process is executed on the binarized image data (step S204). The block processing includes processing for specifying each connected component for “0 (dark)” and “1 (bright)” in the binarized image data and labeling processing for labeling each connected component. Here, the area occupied by each connected component specified is expressed by the number of dots corresponding to the pixel of the camera 53.

  When the binarized image data is acquired, a connected component corresponding to a foreign substance, that is, a defective area is specified from the “0 (dark)” connected components obtained from the binarized image data (step S205). .

  More specifically, using the masking data set in advance, the masking means 62 masks the sheet area 90b (see FIG. 9), which is the non-inspected area, and inspects the pocket area 90a (see FIG. 9). After setting as a target area, a defective area is specified. Note that the processing function of the image processing apparatus 54 that executes the processes according to steps S204 and S205 constitutes the foreign matter detection means in the present embodiment.

  When the defective area is specified, the area Sx of the defective area is calculated (step S206), and it is determined whether or not the area Sx of the defective area is equal to or less than a preset determination reference value So (step S207). That is, it is determined whether or not the area Sx of the defective area is within the allowable range.

  Here, when the area Sx of the defective area is equal to or smaller than the determination reference value So, a non-defective product determination is performed in step S208, and this process is temporarily ended. On the other hand, when the area Sx of the defective area is larger than the determination reference value So, the defect is determined in step S209, and the process is temporarily terminated.

  Note that the processing of the inspection routine is executed for each tablet 5 on the container film 3 and includes at least one tablet 5 that is determined to be defective on the same sheet when it is cut into the PTP sheet 1 later. The sheet is judged to be defective and discharged.

  As described above in detail, according to the present embodiment, the imaging area 88 for one screen is divided into two in the horizontal direction around the optical axis of the camera 53 as the imaging element of the camera 53, and the two divided A CCD area sensor 53a that performs output from an area in parallel from two different channels is used. As a result, high-speed continuous shooting is possible, and inspection efficiency can be improved.

  In the present embodiment, the position corresponding to the boundary between the left imaging area 88A and the right imaging area 88B obtained by dividing the imaging area 88 of the CCD area sensor 53a on the imaged image data is the inspection target area. The camera 53 is arranged so as not to overlap with a certain pocket region 90a.

  As a result, the output level of each channel of the CCD area sensor 53a does not match, and a luminance difference occurs at a position corresponding to the boundary between the left imaging area 88A and the right imaging area 88B on the captured image data. Even if it has, it can test | inspect appropriately about the area | region to be examined, without receiving the influence.

  Specifically, under the above configuration, for example, the tablet 5 shown in FIG. 10A is imaged by the CCD area sensor 53a, and a luminance image 95 composed of image signals output from each channel [FIG. 10B]. In the differential image 96 (see FIG. 10 (c)) obtained by differential processing of the luminance image 95, a vertical line 97 appears in the central portion. The portion where the vertical line 97 appears is a sheet portion region which is a masked non-inspection target region.

  As a result, it is possible to suppress the occurrence of the problem that the linear foreign matter 98 such as hair attached to the tablet 5 and the vertical line 105 overlap and the linear foreign matter 98 cannot be detected. Moreover, when the linear foreign material 98 has not adhered to the tablet 5, generation | occurrence | production of the malfunction which misdetects the vertical line 97 as a linear foreign material can be suppressed.

  As a result, according to the present embodiment, it is possible to suppress a decrease in inspection accuracy while improving inspection efficiency.

  In addition, in this embodiment, when the position of the camera 53 is set, the image captured by the camera 53 on the monitor 55 and the boundary between the left imaging area 88A and the right imaging area 88B obtained by dividing the imaging area 88 into two. The center reference line R indicating the position corresponding to the part is displayed, and the camera position adjustment mechanism 57 capable of adjusting the position of the camera 53 is provided. As a result, the operator can align the camera 53 while looking at the monitor 55.

  As a result, the alignment operation of the camera 53 can be performed more easily and more easily, and the work efficiency can be improved. Furthermore, since the camera 53 can be aligned at a more appropriate position, the inspection accuracy can be further improved.

  In addition, it is not limited to the description content of the said embodiment, For example, you may implement as follows. Of course, other application examples and modification examples not illustrated below are also possible.

  (A) In the above embodiment, the case where the content is the tablet 5 is specified, but the type, shape, and the like of the content are not particularly limited, and may be food, for example.

  (B) In the said embodiment, the container film 3 is formed with transparent thermoplastic resin materials, such as PP, and the cover film 4 is formed with aluminum. The material of each film 3 and 4 is not limited to these, You may employ | adopt the thing of another material.

  For example, the container film 3 may be formed of a metal material mainly made of aluminum, such as an aluminum laminate film.

  (C) The arrangement and the number of pocket portions 2 in the PTP sheet 1 are not limited to the above embodiment (2 rows, 14 pieces), and for example, a type having 12 pocket portions in 3 rows, PTP sheets having various arrangements and numbers can be used.

  (D) In the above embodiment, the present invention is applied to the reflected light type inspection device 22 for inspecting the appearance defect of the tablet, but the configuration of the inspection device is not limited to this.

  For example, the present invention may be applied to a transmitted light type inspection apparatus. Moreover, you may apply to the test | inspection apparatus which test | inspects in the middle of conveyance of the container film 3 (PTP film 6) after attaching the cover film 4. FIG.

  Moreover, you may apply to the inspection apparatus which test | inspects the external appearance defect of a sheet | seat part by making a sheet | seat part area | region into a test | inspection area | region. In the case where the sheet area is the inspection target area, the boundary between a plurality of areas in which the imaging area 88 is divided outside the PTP sheet 1, for example, at the punching line or scrap position when the PTP sheet 1 is punched. It is preferable to match the positions corresponding to the parts. For example, as will be described later, if the imaging region 88 is divided into two in the vertical direction, the imaging region is formed in a punching line or scrap portion between two PTP sheets 1 in the film transport direction (X-axis direction) of the container film 3. Positions corresponding to the boundary portions of a plurality of areas divided by 88 can be easily aligned.

  (E) In the said embodiment, although it becomes the structure which irradiates infrared light with respect to the container film 3, irradiation light is not limited to this. For example, it is good also as a structure which irradiates near infrared light and visible light.

  (F) In the above embodiment, as the imaging device of the camera 53, the imaging area 88 is divided into two in the horizontal direction, and interline transfer is performed in parallel from two different channels for output from the two divided areas. A CCD area sensor 53a of the type is employed.

  The configuration of the CCD area sensor is not limited to this. For example, a CCD area sensor such as a full frame transfer method, a frame transfer method, or a frame interline transfer method may be employed.

  The imaging area 88 may be divided into two in the vertical direction, or the imaging area 88 may be divided into three or more areas. A specific example is the example shown in FIG.

  In the CCD area sensor 53a shown in FIG. 11, the imaging area 88 for one screen is divided into two parts each in the horizontal direction and the vertical direction around the optical axis of the camera 53, for a total of four parts. Is performed in parallel from four different channels. In such a configuration, the charges read from the light receiving unit 81 included in each of the divided regions 88A, 88B, 88C, 88D are respectively transferred to a predetermined vertical transfer unit 82 (82A, 82B, 82C, 82D) and horizontal transfer unit 83 ( 83A, 83B, 83C, 83D) and output from a predetermined output amplifier 85 (85A, 85B, 85C, 85D).

  (G) In the above-described embodiment, it is easy to detect linear foreign matters such as hair and fiber scraps by performing differential processing. However, the differential processing may be omitted. Moreover, the foreign material used as a detection target is not limited to linear foreign materials, such as hair and fiber waste. For example, according to the above embodiment, it is also possible to detect powder such as tablet powder in which the shape of the defective area is substantially circular.

  (H) In the above embodiment, based on the image of the container film 3 and the center reference line R displayed on the display screen 55a of the monitor 55, the operator operates the keyboard 56 and the like to activate the camera position adjustment mechanism 57. The position of the camera 53 is adjusted.

  For example, the position of the pocket portion 2 or the like is detected based on the captured image data, or the pocket portion 2 based on the shape and dimensions of the PTP sheet 1, pocket portion 2, tablet 5, or the like registered in advance. For example, the camera position adjustment mechanism 57 may automatically adjust the position of the camera 53 in accordance with this position.

  The monitor 55 may be omitted, and the position of the camera 53 may be adjusted without looking at the monitor 55, for example, by looking at a predetermined scale.

  The camera position adjustment mechanism 57 may be omitted, and the relative position relationship between the camera 53 and the container film 3 may be adjusted by adjusting the position of the container film 3. For example, a configuration in which the relative positional relationship between the camera 53 and the container film 3 can be adjusted by moving the container film 3 along the X-axis direction, which is the film conveyance direction, under a configuration in which the imaging region 88 is divided into two in the vertical direction. It is good.

  It is good also as a structure provided with the mechanism which can displace the conveyance path | route of the container film 3 along the Y-axis direction which is a film width direction.

  (I) The configuration of the camera position adjustment mechanism 57 is not limited to the above embodiment. For example, the camera position adjusting mechanism 57 according to the above embodiment includes a Z-axis moving mechanism 72 for sliding the camera 53 along the Z-axis direction that is the normal direction of the container film 3, and the Z-axis moving mechanism 72 ( Y-axis moving mechanism for slidingly moving the camera 53) along the Y-axis direction that is the film width direction of the container film 3 (the direction orthogonal to the Z-axis direction and the direction orthogonal to the X-axis direction that is the film transport direction) 73.

  Instead of or in addition to this, an X-axis moving mechanism for sliding the camera 53 in the X-axis direction may be provided.

  (J) In the above embodiment, the tablet 5 is judged to be good or bad depending on whether or not the area Sx of the defective area is equal to or less than a predetermined determination reference value So. It is not limited.

  For example, the configuration may be such that the pass / fail judgment is performed based on the perimeter length, major axis, major axis / minor axis ratio, area / perimeter length ratio, and the like of the defective area. Thereby, linear foreign substances, such as hair in which it is an elongate shape and the area value tends to become relatively small, can be detected more appropriately.

  DESCRIPTION OF SYMBOLS 1 ... PTP sheet, 2 ... Pocket part, 3 ... Container film, 4 ... Cover film, 5 ... Tablet, 10 ... PTP packaging machine, 22 ... Inspection apparatus, 52 ... Illumination device, 53 ... Camera, 53a ... CCD area sensor, 54 ... Image processing device, 55 ... Monitor, 57 ... Camera position adjustment mechanism, 67 ... Differential processing means, 88 ... Imaging region, 88A ... Left imaging region, 88B ... Right imaging region, R ... Central reference line.

Claims (6)

An inspection apparatus used in the manufacture of a PTP sheet in which contents are stored in a pocket portion formed in a belt-shaped container film to be transported, and a cover film is attached so as to close the pocket portion,
Irradiating means for irradiating the container film containing the contents with predetermined light;
Imaging means having an imaging element capable of imaging the contents irradiated with the light and the container film;
An image processing device for processing an image signal output from the imaging means,
The image sensor is
A CCD area sensor in which an imaging region is divided into a plurality of regions and outputs from the divided regions are performed in parallel from different channels,
The imaging means is arranged so that a position corresponding to a boundary portion of a plurality of divided areas of the imaging area is a position that does not overlap a predetermined inspection target area on an image captured by the imaging element. Inspection device characterized by Display means capable of displaying an image picked up by the image pickup means and a line indicating positions corresponding to boundaries of a plurality of areas divided in the image pickup area;
The inspection apparatus according to claim 1, further comprising a position adjusting unit capable of adjusting a position of the imaging unit. The image processing apparatus includes:
Differential processing means for performing differential processing on the image captured by the imaging means;
The inspection apparatus according to claim 1, further comprising a foreign substance detection unit capable of detecting a foreign substance existing in the inspection target area based on the differential image subjected to the differentiation process.   A PTP packaging machine comprising the inspection device according to claim 1. It is an inspection method used in manufacturing a PTP sheet in which contents are stored in a pocket portion formed in a belt-shaped container film to be conveyed, and a cover film is attached so as to close the pocket portion,
Irradiating the container film containing the contents with predetermined light using an irradiation means,
The contents irradiated with the light and the container film are imaged using an imaging means having an imaging element,
An image signal output from the imaging means is processed using an image processing device,
The image sensor is
A CCD area sensor in which an imaging region is divided into a plurality of regions, and outputs from the divided regions are performed in parallel from different channels,
The imaging means is arranged so that a position corresponding to a boundary portion of the plurality of divided areas of the imaging area is a position that does not overlap a predetermined inspection target area on an image captured by the imaging element. Inspection method characterized by A method for producing a PTP sheet, comprising the inspection method according to claim 5.

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