JP6046585B2 - 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, after the cover film is attached, it is necessary to inspect for sheet defects such as foreign matter sandwiched between the two films, wrinkles and tears generated on the cover film, and the like.

  Generally, the container film is formed of a transparent resin material or the like, while the cover film is formed of an opaque metal foil such as aluminum. For this reason, conventionally, a reflected light type inspection apparatus has been used in inspection relating to sheet defects performed after the cover film is attached (see, for example, Patent Document 1).

  For example, in the reflected light type inspection apparatus 89 shown in FIG. 11, an illumination 92 is provided on the container film 91 side of the PTP sheet 90, and the PTP sheet 90 is irradiated with light from here. And the light which permeate | transmitted the transparent container film 91 and reflected on the cover film 93 which consists of aluminum etc. is imaged with the camera 94 provided in the container film 91 side similarly to the illumination 92. FIG. Thereby, based on the captured image, it is possible to detect sheet defects such as the flange 93a of the cover film 93 and the foreign matter 95 sandwiched between the two films 91 and 93.

JP 2006-105852 A

  However, in recent years, a cover film using a thin paper such as glassine paper as a base material is sometimes used for the PTP sheet from the viewpoint of ensuring the air permeability of the pocket portion.

  Since the cover film made of glassine paper or the like is translucent, the light irradiated from the illumination diffuses in the cover film when the inspection is performed with a conventional reflected light type inspection device, and the entire cover film is covered. Images are captured as if they are brightly shining. For this reason, the part with a wrinkle in a cover film and the part without a wrinkle appear in the same way without a difference in brightness, and there exists a possibility that it may become difficult to detect a wrinkle.

  On the other hand, when the cover film is translucent, it is also conceivable to use a transmitted light type inspection apparatus in the inspection relating to the sheet defect performed after the cover film is attached.

  For example, in the transmitted light type inspection apparatus 99 shown in FIG. 12, the illumination 102 is provided on the container film 101 side of the PTP sheet 100, and light is irradiated to the PTP sheet 100 from here. The light transmitted through the transparent container film 101 and the translucent cover film 103 is imaged by the camera 104 provided on the cover film 103 side of the PTP sheet 100. At this time, the portion where the cover film 103 approaches and becomes a ridge 103a appears darker than the other portions because the cover film 103 overlaps, so the fold 103a is detected based on the difference in brightness from the normal sheet portion having no abnormality. It becomes possible.

  However, when such a transmitted light type inspection apparatus 99 is used, with respect to the foreign material 105 sandwiched between the films 101 and 103, the light emitted from the illumination 102 is diffused by the cover film 103, and the camera is more effective than the foreign material 105. Since the cover film 103 located on the 104 side is brightly shining, it may be difficult to detect appropriately when the foreign material 105 is a relatively small foreign material such as hair or tablet powder.

  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 capable of dramatically improving inspection accuracy when inspecting a PTP sheet. is there.

  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. A PTP sheet inspection apparatus in which contents are stored in a pocket portion formed in a transparent container film, and a translucent cover film is attached to the container film so as to close the pocket portion,
Irradiation means capable of irradiating predetermined light from the cover film side to the PTP sheet;
The irradiation means is provided on the opposite side through the PTP sheet, and an imaging means capable of imaging transmitted light that is irradiated from the irradiation means and passes through the PTP sheet;
An image processing device for processing an image signal output from the imaging means,
The image processing apparatus includes:
Based on image data obtained from the image signal, there is provided a defect detection means capable of detecting at least a foreign matter sandwiched between the container film and the cover film and a sheet defect including wrinkles or tears generated in the cover film. Inspection device characterized by that.

  The same applies to the following, but the term “transparent film” as used herein refers to a film having the property of transmitting light (translucency), having extremely high light transmittance, and the other side through the film. This refers to those that can be seen through. In contrast, a “translucent film” has translucency, but the transmitted light is diffused or has low transmittance, so the shape of the object on the other side through the film is clear. It is in a state where it cannot be recognized or cannot be recognized at all.

  In addition, “transparent” and “semi-transparent” are expressions indicating the material of the translucent film and are irrelevant to the presence or absence of color. Accordingly, the “transparent” or “translucent” film includes, for example, a “colorless transparent” or “colored translucent” film as well as a “colorless transparent” or “colorless translucent” film.

  According to the above means 1, predetermined light is irradiated from the cover film side to the PTP sheet in which the translucent cover film is attached to the transparent container film, and the transmitted light transmitted through the PTP sheet is imaged. Imaged by means. A sheet defect is detected based on the acquired image data.

  The “sheet defect” referred to herein includes, for example, foreign matter sandwiched between the two films, wrinkles and tears generated on the cover film, and the like.

  For example, in luminance image data captured under normal transmitted light, a portion where foreign matter is sandwiched between the two films or a portion where wrinkles are generated on the cover film is darker than other normal portions. On the other hand, the part where the cover film is torn is brighter than the other normal parts. Therefore, a sheet defect can be detected by setting a predetermined threshold value in consideration of the difference in brightness (brightness difference). Here, a plurality of threshold values are set in order to detect a wrinkle of a cover film that appears darker than other normal parts or a tear of a cover film that appears brighter than other normal parts.

  As a result, when inspecting a sheet defect related to a PTP sheet having a translucent cover film, it is possible to dramatically improve inspection accuracy without being affected by light diffusion in the cover film as much as possible. it can.

  In addition, according to the test | inspection apparatus which concerns on this means, there exists a possibility that it may become difficult to detect the foreign material adhering to the surface of a cover film by the influence of a cover film like the above (refer G3 of FIG. 8). However, foreign materials attached to the surface of the container film or the cover film can be removed in a later process, unlike foreign materials sandwiched between the two films. Even if it is not detected by the inspection device, it is difficult to cause a particular problem.

  However, foreign matter adhering to the surface of the container film can be properly detected by the inspection apparatus according to this means, as in the case of foreign matter sandwiched between both films (see G2 in FIG. 8). Since the transparent container film is generally formed of a resin material such as polypropylene (substance that tends to be negatively charged), foreign matter such as hair and powder (substance that tends to be positively charged) easily adheres due to static electricity or the like. Therefore, it is a great advantage to be able to properly detect foreign matter adhering to the surface of the container film. On the other hand, for example, in the conventional transmission type inspection apparatus shown in FIG. 12, it is difficult to detect the foreign matter adhering to the surface of the container film as well as the foreign matter sandwiched between the two films.

  Mean 2. The inspection apparatus according to means 1, wherein the cover film is formed by using thin paper as a main material (base material).

  Here, “formed with thin paper as a main material” means not only when it is formed of thin paper alone, but also includes thin paper on which a resin film layer, a heat seal layer, and the like are stacked. “Thin paper” includes “glassine paper” and “paraffin paper”.

  Thin paper such as glassine paper is excellent in air permeability and excellent in strength and rupture property among various substrates excluding metal foil, and is suitable as a material for a cover film.

  Furthermore, when the cover film is formed of thin paper as a main material, adhesion of foreign matters such as hair and powder due to the influence of static electricity or the like can be reduced as compared with the case where the cover film is formed of a resin material or the like.

  Further, even if a foreign matter adheres to the surface of the cover film, the foreign matter falls by its own weight, for example, during the transport of the PTP sheet, compared to the case where the foreign matter adheres to the surface of the container film. Is often easily removed from

  That is, as described above, in the inspection apparatus according to the present means, foreign matter adhering to the surface of the cover film may be difficult to detect due to the influence of light diffusion or the like in the cover film. Even if it is a simple structure, since a foreign material becomes difficult to adhere with respect to a cover film, a big malfunction will not arise.

  Especially when the PTP sheet is transported vertically with the cover film turned sideways, when the PTP sheet is transported horizontally with the cover film facing down, or when the cover film is tilted downward In the process in which the PTP sheet is transported obliquely, foreign matter is likely to fall during the transport of the PTP sheet. Therefore, in the transport process, if the sheet defect inspection is performed by the inspection apparatus according to this means, Defects are less likely to occur.

  On the other hand, the foreign matter adhering to the surface of the cover film that can be easily removed in this way is not detected by the inspection apparatus, and thus, even a non-defective PTP sheet that should not be considered a defective product is treated as a defective product. Useless work can be omitted and inspection efficiency can be increased.

  Of course, even if foreign matter continues to adhere to the surface of the cover film, as described above, such foreign matter can be removed in a subsequent process, so that a particular problem is unlikely to occur even if it is not detected by the inspection apparatus.

  Means 3. The irradiating means includes irradiating light restricting means for restricting passage of light with an incident angle with respect to the PTP sheet equal to or smaller than a predetermined angle out of light emitted from a predetermined light emitting means. Or the inspection apparatus of 2.

  According to the means 3, the light whose incident angle is equal to or smaller than the predetermined angle is restricted from passing by the irradiation light limiting means, and is not irradiated to the PTP sheet. In other words, only the light whose incident angle exceeds the predetermined angle is irradiated to the PTP sheet.

  If the PTP sheet in which the cover film is torn is irradiated with normal light that does not pass through the irradiation light limiting means, as described above, on the image data imaged by the imaging means, the cover film The part where the tear is generated appears brighter than other normal parts.

  On the other hand, when the PTP sheet in which the cover film is torn is irradiated with light through the irradiation light limiting means, it passes through the portion where the tear has occurred and passes from the predetermined light emitting means to the imaging means. Directly incident light is eliminated or reduced. That is, on the image data picked up by the image pickup means, a portion where the cover film is broken appears darker than other normal portions of the cover film that emit diffused light.

  Therefore, when the light is irradiated through the irradiation light limiting means, the portion where the cover film is wrinkled and the portion where the cover film is torn are also darker than other normal portions. It becomes. As a result, it is not necessary to set a plurality of threshold values in order to detect these sheet defects. For example, it is possible to detect them collectively by using one threshold value, so that the inspection process can be simplified. it can.

  In order to further enhance the above effect, for example, it is preferable that the “incident angle” is set to be equal to or less than “a predetermined angle θ that is a half of the field angle 2θ of the lens portion of the imaging unit”.

  Furthermore, according to the present means 3, it is possible to further make it difficult to detect foreign matter adhering to the surface of the cover film, and it is possible to enhance the effect of the above means 2. In other words, by preventing foreign matter adhering to the surface of the cover film that can be easily removed from being detected by the inspection device, wasteful work such as handling a defective PTP sheet, which should not be considered a defective product, is handled. This can be omitted and the inspection efficiency can be increased.

  Means 4. The irradiation light limiting means has a plurality of triangular protrusions arranged side by side on the incident surface on which the light emitted from the light emitting means is incident, and the emission surface from which the light is emitted is formed flat. 4. The inspection apparatus according to means 3, which is constituted by a prism sheet.

  According to the means 4, the irradiation light limiting means can be easily realized with a relatively simple configuration, and the inspection apparatus can be simplified.

  Means 5. The inspection apparatus according to any one of means 1 to 4, wherein the irradiating means is configured to be able to irradiate infrared light as the predetermined light.

  Infrared light is likely to pass through a translucent cover film made of glassine paper or the like. Therefore, by using infrared light as irradiation light, compared to the case where visible light such as blue light is used, the above means 1 etc. The effect can be further enhanced.

  In addition, since infrared light is used, even when characters, designs, and the like are printed on the cover film, it is difficult to be affected by this, and the possibility that the inspection accuracy may be reduced can be reduced.

  Means 6. 6. The inspection apparatus according to claim 1, wherein the image processing apparatus includes a determination unit that can determine the type of sheet defect detected by the defect detection unit.

  According to the means 6, by providing the discrimination means, it is possible to eliminate a wasteful work that treats even a non-defective PTP sheet that is not supposed to be a defective product, and improves inspection efficiency. it can.

  For example, the type of sheet failure can be determined by determining the size, shape, and the like of a portion (for example, a dark portion) detected as a sheet failure in the captured image data.

  As a specific example, for example, when the shape of the defective sheet portion is long and wide, it can be identified as a wrinkle of the cover film, and when the shape of the defective sheet portion is long and narrow, the hair Can be determined. Further, when the shape of the defective sheet portion is circular and the size is small, it can be distinguished from powder such as tablet powder. Thus, when only a small tablet powder adheres, it can be handled not as a defective sheet but as a non-defective product.

  Mean 7 A PTP packaging machine comprising the inspection device according to any one of means 1 to 6.

  By providing the inspection apparatus in the PTP packaging machine as in the above means 7, 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.

(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 cross-sectional schematic diagram for demonstrating the structure of an illuminating device. It is a schematic diagram for demonstrating the function of an angle transmittance control filter. It is a flowchart which shows the test | inspection routine performed by a test | inspection apparatus. It is a schematic diagram which shows schematic structure of an inspection apparatus. It is a graph which shows an example of the change of the luminance level in the luminance image data of the PTP film which has various sheet defects. It is a graph which shows an example of the change of the brightness | luminance level in the brightness image data of the PTP film which has various sheet | seat defects based on another embodiment. It is a schematic diagram which shows schematic structure of the conventional reflected light type inspection apparatus. It is a schematic diagram which shows schematic structure of the conventional transmitted light type inspection apparatus.

  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 formed of a colorless and transparent thermoplastic resin material such as PP (polypropylene) or PVC (polyvinyl chloride).

  On the other hand, the cover film 4 is formed by forming a seal layer for attaching to the container film 3 with respect to the white translucent glassine paper, and at least a portion corresponding to the pocket portion 2 has air permeability. . The cover film 4 is printed with characters (not shown) and decorative designs.

  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. This inspection device 22 mainly performs inspections related to tablet defects such as whether or not the tablets 5 are reliably filled in the pockets 2, whether or not the tablets 5 are abnormal, and whether or not foreign matter is mixed into the pockets 2. belongs to.

  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.

  An inspection device 29 is disposed between the film receiving roll 20 and the tension roll 27 along the transport path of the PTP film 6. This inspection device 29 is for mainly inspecting for sheet defects such as foreign matter G1 such as hair and tablet powder sandwiched between the films 3 and 4, and wrinkles 4a and tears 4b generated on the cover film 4. (See FIG. 8).

  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 devices 22 and 29 determine 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 a discharge unit.

  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 device 29 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 device 29.

  As shown in FIG. 4, the inspection device 29 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 an output means, a keyboard 56 as an input means, and the like. ing.

  Here, the configuration of the illumination device 52 will be described in more detail. The illuminating device 52 in this embodiment is arrange | positioned at the cover film 4 side, and irradiates predetermined light with respect to the PTP film 6 from the cover film 4 side (refer FIG. 3, 8).

  Moreover, as shown in FIG. 5, the illuminating device 52 has the LED mounting board 57 and the diffusion plate 58 which covers this, and is comprised so that surface emission is possible. The LED mounting substrate 57 and the diffusing plate 58 constitute light emitting means in the present embodiment.

  On the LED mounting substrate 57, a number of infrared LEDs 57a (infrared light sources) capable of emitting infrared light as predetermined light are arranged. Infrared light has a higher transmittance than visible light, so that inspection with higher accuracy is possible. Although a colored (colored) film may be employed as the container film 3 or the cover film 4, even in such a case, it is easy to ignore the light reducing element due to the coloring.

  Further, the illumination device 52 includes an angle transmittance control filter 59 as irradiation light limiting means so as to be arranged in parallel with the diffusion plate 58.

  The angular transmittance control filter 59 in this embodiment is configured by a prism sheet. More specifically, the angular transmittance control filter 59 (prism sheet) includes an incident surface 59a facing the diffusion plate 58 and an exit surface 59b located on the opposite side (PTP film 6 side).

  While the emission surface 59b is formed flat, a plurality of protrusions 59c having a triangular cross section are arranged in parallel along the predetermined direction on the incidence surface 59a.

  As shown in FIG. 6, the angular transmittance control filter 59 in the present embodiment is configured to be able to totally reflect infrared light emitted from the diffusion plate 58 along at least the optical axis L1 direction of the camera 53, and The light within the range of the angle of view 2θ of the lens portion of the camera 53 is configured to be totally reflected.

  Thereby, among the light irradiated from the diffusing plate 58, the light whose incident angle with respect to the PTP film 6 is equal to or smaller than the predetermined angle θ is restricted from passing and is not irradiated to the PTP film 6. In other words, only the light whose incident angle exceeds the predetermined angle θ is irradiated to the PTP film 6.

  Next, the configuration of the camera 53 will be described in more detail. The camera 53 is disposed on the container film 3 side opposite to the lighting device 52 through the PTP film 6 (see FIGS. 3 and 8). In the present embodiment, a CCD camera that is sensitive to at least infrared light is employed as the camera 53. Of course, the present invention is not limited to this, and a CMOS camera may be employed.

  Thereby, the infrared light irradiated from the illumination device 52 illuminates the PTP film 6, and the light transmitted therethrough is two-dimensionally imaged by the camera 53. The image data captured by the camera 53 is converted into a digital signal (image signal) inside the camera 53 and then input to the image processing device 54 in the form of a digital signal.

  As shown in FIG. 4, the image processing device 54 includes an image memory 61 corresponding to the camera 53, a masking means 62, a binarizing means 63, a determination memory 64, an inspection result and statistical data memory 65, and a camera timing control means 66. In addition, the image forming apparatus includes a CPU and an input / output interface 67, and can perform image data processing and sheet defect determination (inspection), which will be described later.

  Two-dimensional image data (luminance image data) captured by the camera 53 is converted into a digital signal and stored in the image memory 61. Further, at the time of inspection, the image data is subjected to masking processing by the masking means 62 and then stored again in the image memory 61. Similarly, after being binarized by the binarizing means 63, the image data is again stored. Is remembered.

  The CPU and input / output interface 67 executes various processing programs while using the stored contents of the determination memory 64 and the like, and sends 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 67 also has a function of sending display data to the monitor 55. With this function, binary or grayscale image data, a defect inspection result, and the like can be displayed on the monitor 55. Further, the CPU and input / output interface 67 has a function of inputting data from the keyboard 56.

  The inspection result and statistical data memory 65 stores data such as coordinates relating to image data, 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 67. Further, the CPU and the input / output interface 67 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 PTP film 6 is fed by a predetermined amount, an image is taken in sheet units (for example, punched PTP sheet units) by the camera 53. .

  Next, an inspection procedure relating to sheet defects performed by the inspection device 29 will be described with reference to a flowchart of FIG.

  First, in step S1, the PTP film 6 (PTP sheet 1) to be inspected is irradiated with infrared light from the illumination device 52, and the PTP film 6 irradiated with the infrared light is imaged by the camera 53 (imaging). processing). Thereby, luminance image data of the PTP film 6 is acquired. The acquired luminance image data is stored in the image memory 61 after being converted into a digital signal as described above.

  When the luminance image data is acquired, in step S2, binarized image data is formed by the binarizing means 63 and stored again in the image memory 61 (binarization processing). More specifically, the luminance image data is converted into binarized image data by setting “1 (bright)” above the threshold δ0 and “0 (dark)” below the threshold δ0 (see FIG. 9). FIG. 9 is a graph showing an example of a change in luminance level in luminance image data of the PTP film 6 having various sheet defects.

  As shown in FIG. 9, the PTP film 6 appears brighter as the irradiated light is transmitted and diffused as the cover film 4 is normally attached. On the other hand, the part where the foreign matter G1 exists between the two films 3 and 4 and the part where the ridge 4a is generated on the cover film 4 appear dark.

  In addition, in the present embodiment, since the angle transmittance control filter 59 is provided, the light emitted from the illumination device 52 does not directly enter the camera 53 via the tear 4b of the cover film 4, and the cover film. The portion where the tear 4b is generated in 4 will also appear dark.

  That is, a portion where the sheet G is defective, such as a portion where the foreign matter G1 exists or a portion where the cover film 4 has a ridge 4a or a tear 4b is “0 (dark)”. Binary image data having “1 (bright)” is acquired (excluding the area in 2).

  Next, in step S <b> 3, chunk processing is executed on the binarized image data stored in the image memory 61. 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.

  In the subsequent step S4, a connected component corresponding to the foreign matter G1, wrinkle 4a, tear 4b, or the like, that is, a sheet defective area is specified from among “0 (dark)” connected components obtained from the binarized image data.

  More specifically, the masking means 62 performs masking on the area (pocket area) in the pocket portion 2 using preset masking data, and sets the sheet area outside the pocket portion 2 as an inspection area. Thus, the defective sheet area is specified. Note that the processing function of the image processing apparatus 54 that executes the processes according to steps S2 to S4 constitutes a defect detection means in the present embodiment.

  In step S5, the area Sx of each defective sheet area specified in step S4 is calculated.

  In step S6, it is determined whether or not the area Sx of each defective sheet area calculated in step S5 is equal to or smaller than a preset area determination value So. That is, it is determined whether the area Sx of each defective sheet region is within an allowable range.

  Here, when the area Sx of all the defective sheet regions is within the allowable range, the process proceeds to step S7, and the non-defective product is determined. On the other hand, if even one area Sx of the defective sheet area is not within the allowable range, the process proceeds to step S8, and defect determination is performed.

  As described above, the processing of the inspection routine is executed for each sheet unit on the PTP film 6 to be the PTP sheet 1 later, and when the PTP sheet 1 is cut, even one defect is determined on the same sheet. When there is a sheet defect, the sheet is determined to be defective and discharged.

  As described above in detail, according to this embodiment, infrared light is irradiated from the cover film 4 side to the PTP sheet 1 in which the translucent cover film 4 is attached to the transparent container film 3. The transmitted light that has passed through the PTP sheet 1 is imaged by the camera 53. Based on the acquired image data, various sheet defects such as foreign matter G1 existing between the films 3 and 4 and wrinkles 4a and tears 4b generated on the cover film 4 are detected.

  As a result, the inspection accuracy of the PTP sheet 1 having the translucent cover film 4 can be greatly improved without being affected by light diffusion in the cover film 4 as much as possible. Can be planned.

  Furthermore, according to the inspection apparatus 29 according to the present embodiment, the foreign matter G2 (see FIG. 8) adhering to the surface of the container film 3 is properly detected in the same manner as the foreign matter G1 existing between the films 3 and 4. can do. Foreign matter such as hair and tablet powder is likely to adhere to the container film 4 formed of a resin material such as PP due to static electricity or the like. Therefore, it is a great advantage that the foreign matter G2 attached to the surface of the container film 4 can be properly detected.

  On the other hand, since the cover film 4 in the present embodiment is formed using glassine paper as a base material, foreign substances such as hair and tablet powder are less likely to adhere to the container film 3. Even if the foreign matter G3 adheres to the surface of the cover film 4 (see FIG. 8), it is easily removed from the surface of the cover film 4 such as falling by its own weight while the PTP sheet 1 is being conveyed.

  In particular, in the present embodiment, the sheet defect inspection by the inspection device 29 is performed in the process in which the PTP film 6 is vertically conveyed in a state where the cover film 4 is in the horizontal direction (see FIG. 3). When the sheet defect inspection is performed, the possibility that the foreign matter G3 adheres to the surface of the cover film 4 is extremely low.

  If the foreign matter G3 adheres to the surface of the cover film 4, it is difficult to detect the foreign matter G3 by the inspection device 29 according to the present embodiment due to the influence of light diffusion or the like on the cover film 4. However, unlike the foreign matter G1 etc. sandwiched between the films 3 and 4, the foreign matter G3 can be removed in a later process, so that no particular problem occurs even if it is not detected by the inspection device 29. .

  On the contrary, by preventing the foreign matter G3 adhering to the surface of the cover film 4 that can be easily removed from being detected by the inspection device 29, the non-defective PTP sheet 1 that should not be considered a defective product is treated as a defective product. Such useless work can be omitted, and the inspection efficiency can be increased.

  Further, in the present embodiment, an angle transmittance control filter 59 is provided, and light having an incident angle equal to or smaller than a predetermined angle θ is restricted from passing and is not irradiated to the PTP sheet 1. As a result, the foreign matter G3 adhering to the surface of the cover film 4 is further blurred, and the detection thereof is further difficult. As a result, the above effects can be made more reliable.

  In addition, since the angle transmittance control filter 59 is provided, the light irradiated from the illumination device 52 is not directly incident on the camera 53 through the tear 4b of the cover film 4, so that the cover film 4 is broken 4b. The part that is present will appear darker than other normal parts of the cover film 4 that emit diffuse light.

  As a result, all the parts with sheet defects such as the part where the foreign matter G1 is present and the part where the cover 4 has the crease 4a and the tear 4b appear darker than the normal part, so these sheet defects are detected. For this reason, it is not necessary to set a plurality of threshold values, and it is possible to detect them collectively by one threshold value δ0, so that the inspection process can be simplified.

  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. For example, the content such as food or electronic parts is not limited. It may be different from the tablet 5.

  (B) In the above embodiment, the container film 3 is formed of a colorless and transparent thermoplastic resin material such as PP or PVC, and the cover film 4 is formed using a white translucent glassine paper as a base material. The materials 3 and 4 are not limited to these, and other materials may be adopted.

  For example, the container film 3 may be a transparent film and may be formed of other materials. Moreover, you may employ | adopt not only the colorless and transparent container film 3, but colored transparent films, such as red transparency.

  The cover film 4 may also be a translucent film and may be formed of other materials. For example, you may employ | adopt the film formed using the thin paper (for example, paraffin paper) different from glassine paper as a base material. Moreover, not only the white translucent cover film 4 (glassine paper etc.) but a color translucent film (glassine paper etc.), such as yellow translucent, may be employ | adopted, for example. In addition, the cover film 4 does not necessarily need to have air permeability. In other words, the film is not limited to a film using thin paper such as glassine paper as a base material, and for example, a film formed of a translucent resin material or the like may be adopted.

  (C) In the said embodiment, although it has the structure which irradiates infrared light with respect to the PTP sheet 1, irradiation light is not limited to this. For example, it is good also as a structure which irradiates near infrared light and visible light.

  (D) The configuration of the angular transmittance control filter 59 as the irradiation light limiting means is not limited to the above embodiment.

  For example, in the above-described embodiment, the angle transmittance control filter 59 is configured by a prism sheet, but is not limited thereto. For example, sheets having different configurations such as a sheet that has been subjected to a predetermined coating process and a filter that electrically controls transmittance may be employed.

  In the above embodiment, the angle transmittance control filter 59 is configured to totally reflect light within the range of the field angle 2θ of the lens unit of the camera 53. That is, the light whose incident angle with respect to the PTP sheet 1 is equal to or smaller than the predetermined angle θ can be totally reflected.

  However, the present invention is not limited to this, and it is sufficient that the light having an incident angle with respect to the PTP sheet 1 be at least a predetermined angle θ is dimmed. Of course, the limited light is not limited to light whose incident angle is equal to or smaller than a predetermined angle θ that is half the field angle 2θ of the lens portion of the camera 53.

  (E) In the embodiment described above, the illumination device 52 includes the angular transmittance control filter 59, but the angular transmittance control filter 59 may be omitted.

  In the configuration in which the angle transmittance control filter 59 is omitted, the light emitted from the illumination device 52 enters the camera 53 directly through the tear film 4b of the cover film 4. For this reason, on the imaged luminance image data, the part where the foreign matter G1 is sandwiched between the films 3 and 4 and the part where the cover 4 is wrinkled 4a are in other normal parts. On the other hand, it appears darker, but the portion where the cover film 4 is broken 4b appears brighter than other normal portions.

  In such a case, as shown in FIG. 10, a cover film 4 that appears darker than other normal parts, a threshold 4a for detecting the foreign matter G1 sandwiched between the films 3 and 4, These sheet defects can be detected by setting a plurality of threshold values δ1 and δ2 such as setting a threshold value δ2 for detecting the tear 4b of the cover film 4 that appears brighter than other normal parts.

  (F) In the above embodiment, the non-defective product of the PTP sheet 1 is determined based on whether or not the area Sx of the defective sheet region is equal to or smaller than the preset area determination value So. Is not limited to this.

  For example, the configuration may be such that the pass / fail judgment is made based on the perimeter length, major axis, major axis / minor axis ratio, area / perimeter length ratio, etc. of the defective sheet area.

  Further, it may be configured such that the type of the detected sheet failure can be determined, and the non-defective product of the PTP sheet 1 is determined based on the determination result. As a result, it is possible to eliminate a wasteful operation of handling a defective PTP sheet 1 that should not be considered a defective product as a defective product, and to improve inspection efficiency. The function of performing such discrimination processing constitutes the discrimination means in this embodiment.

  For example, when the shape of the defective sheet region is long and wide, it can be determined as the ridge 4a of the cover film 4, and when the shape of the defective sheet region is long and narrow, it is determined as hair. be able to. Further, when the shape of the defective sheet area is circular and the size is small, it can be determined as a powder such as tablet powder. Thus, when only a small tablet powder adheres, it can be handled not as a defective sheet but as a non-defective product.

  (G) In the above-described embodiment, the sheet defect inspection by the inspection device 29 is performed in the process in which the PTP film 6 is conveyed along the vertical direction, but the inspection position by the inspection device 29 is limited to this. Is not to be done.

  For example, it is good also as a structure which has arrange | positioned the inspection apparatus 29 corresponding to the position where the PTP film 6 is conveyed in the horizontal direction, or the position conveyed diagonally.

  However, the process in which the PTP film 6 is vertically conveyed with the cover film 4 turned sideways, the process in which the PTP film 6 is horizontally conveyed with the cover film 4 faced down, It is preferable that a sheet defect inspection is performed by the inspection device 29 in a process in which the PTP film 6 is conveyed obliquely in a state of being directed downward.

  In such a process, the foreign matter G3 adhering to the surface of the cover film 4 is likely to fall during the transport of the PTP film 6, so that the foreign matter G3 is not detected by the inspection device 29 and should be originally a defective product. Therefore, it is possible to eliminate a wasteful operation that treats even a non-defective PTP sheet 1 as a defective product, thereby improving the inspection efficiency.

  Alternatively, the sheet punching device 37 may perform a sheet defect inspection by the inspection device 29 at a stage after the PTP film 6 is punched into one PTP sheet. For example, the belt member of the conveyor 39 is formed of a translucent member, and the PTP sheet 1 is transported by the conveyor 39, and light is applied to the PTP sheet 1 from the lower side of the conveyor 39 to perform a sheet defect inspection. It is good.

  (G) In the said embodiment, although it becomes the structure which test | inspects sheet | seat defects, such as the foreign material G1 which exists between both the films 3 and 4, and the wrinkles 4a and tear 4b which arose in the cover film 4, it becomes an inspection item. The sheet defect is not limited to this. For example, the cover film 4 may be inspected for a sealing failure (adhesion failure) or the like.

  DESCRIPTION OF SYMBOLS 1 ... PTP sheet, 2 ... Pocket part, 3 ... Container film, 4 ... Cover film, 5 ... Tablet, 6 ... PTP film, 10 ... PTP packaging machine, 29 ... Inspection apparatus, 52 ... Illumination apparatus, 53 ... Camera, 54 ... Image processing device, 59 ... Angular transmittance control filter.

Claims (1)

A PTP sheet inspection apparatus in which contents are stored in a pocket portion formed in a transparent container film, and a translucent cover film is attached to the container film so as to close the pocket portion,
Irradiation means capable of irradiating predetermined light from the cover film side to the PTP sheet;
The irradiation means is provided on the opposite side through the PTP sheet, and an imaging means capable of imaging transmitted light that is irradiated from the irradiation means and passes through the PTP sheet;
An image processing device for processing an image signal output from the imaging means,
The image processing apparatus includes:
Based on image data obtained from the image signal, there is provided a defect detection means capable of detecting at least a foreign matter sandwiched between the container film and the cover film and a sheet defect including wrinkles or tears generated in the cover film. Inspection device characterized by that.

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