JP6448697B2 - Inspection apparatus, PTP packaging machine, and PTP sheet manufacturing method - Google Patents

Description

  The present invention relates to an inspection apparatus, a PTP packaging machine, and a method for manufacturing a PTP sheet that inspect for mixing of different varieties using spectroscopic analysis.

  In general, a PTP sheet is composed of a container film in which a pocket portion filled with an object such as a tablet is formed, and a cover film that is attached to the container film so as to seal the opening side of the pocket portion. Yes.

  When manufacturing the PTP sheet, a different kind mixing inspection for checking the mixing of different kinds is performed. As a method of such inspection, near-infrared light is irradiated onto an object, the reflected light is dispersed with a spectroscope, and spectral data obtained by imaging it are analyzed as principal components to detect the inclusion of different varieties. How to do is known.

  In recent years, there has been proposed an inspection apparatus capable of simultaneously inspecting objects filled in a plurality of pocket portions aligned in a row in the width direction of a container film (see, for example, Patent Document 1).

JP 2010-175528 A

  However, there are many cases where the position of the object is not determined in the pocket portion to be filled, and the position of the object is different in each of the plurality of pocket portions.

  Therefore, under the configuration in which the container film is intermittently conveyed as in Patent Document 1 and the imaging process is performed while the container film is stopped, for example, as illustrated in FIG. 13, imaging is performed for a plurality of pocket portions 91 arranged in a row. When the processing is performed only once at a predetermined timing, some of the objects 92 are not located in the imaging range E (refer to the scattered points in the figure), and the spectrum data related to the objects 92 are There is a possibility that it cannot be obtained.

  Therefore, in the configuration according to Patent Document 1, it is necessary to perform imaging processing many times while repeatedly carrying and stopping in a range where an object can exist, and there is a possibility that it takes a lot of time for data acquisition. .

  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, a PTP packaging machine, and a method for manufacturing a PTP sheet that can increase the speed of inspection for mixing different types of products using spectroscopic analysis. 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 manufacturing a PTP sheet in which an object is stored in a pocket portion formed in a container film, and a cover film is attached so as to close the pocket portion,
Irradiating means capable of irradiating near-infrared light to the object to be continuously conveyed;
A spectroscopic means capable of spectroscopically entering the reflected light reflected from the object irradiated with the near infrared light through a predetermined slit;
An imaging unit capable of capturing a spectral image of the reflected light spectrally separated by the spectral unit;
Spectral data acquisition means capable of acquiring spectral data based on the spectral image;
Analysis means capable of detecting different varieties by performing predetermined analysis processing (for example, principal component analysis) based on the spectrum data;
An inspection apparatus comprising: an imaging timing control unit capable of executing an imaging process (exposure process) by the imaging unit in an imaging cycle satisfying the following relational expressions (1), (2), and (3):

R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes.

Mean 2. An inspection apparatus used in manufacturing a PTP sheet in which an object is stored in a pocket portion formed in a container film, and a cover film is attached so as to close the pocket portion,
Irradiating means capable of irradiating near-infrared light to the object to be continuously conveyed;
A reflected light reflected from the object irradiated with the near-infrared light, an optical lens made of a telecentric lens on both sides, and a spectroscopic means capable of spectroscopically entering through a predetermined slit;
An imaging unit capable of capturing a spectral image of the reflected light spectrally separated by the spectral unit;
Spectral data acquisition means capable of acquiring spectral data based on the spectral image;
Analysis means capable of detecting different varieties by performing a predetermined analysis process based on the spectrum data;
An inspection apparatus comprising: an imaging timing control unit capable of executing an imaging process by the imaging unit in an imaging cycle that satisfies the following relational expressions (1), (2), and (3):
R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes.
According to the means 1 and 2, since the imaging process is performed while transporting without stopping the object, the transport direction imaging range that can be imaged by one imaging process can be widened to the slit width or more. It is possible to reduce the number of imaging operations for acquiring spectral data necessary for analysis.

  In addition, since the imaging process is performed in the imaging cycle T in this means, the spectrum of the object can be imaged at least once without being affected by the background regardless of the position of the object in the pocket. it can.

  In addition, when tablets (uncoated tablets) formed by mixing various active ingredients and excipients and compressing them are used as an object, the tablets are not microscopically homogeneous, There is also the influence of unevenness, and even for the same tablet, there is a possibility that the data at each measurement point varies greatly and the uniformity cannot be maintained.

  In view of this, when a plurality of measurement points on an object are captured and spectrum data is acquired under a configuration in which an imaging process is performed while the container film is intermittently transported as in Patent Document 1, spectrum data is acquired. Therefore, it is indispensable to perform a process of averaging these, and the analysis process may take time.

  On the other hand, in this means, since the imaging process is performed while the object is being conveyed, the spectrum at each measurement point is integrated, and the predetermined imaging range is averaged without performing a calculation process afterwards. Spectra can be acquired.

  As a result, it is possible to increase the speed of inspection for mixing different types using spectroscopic analysis.

  In order to enhance the above-described effects, it is preferable that the imaging process is continuously executed while the transport amount of the object is at least two pixels of the imaging device of the imaging unit.

Means 3 . A PTP wrapping machine for manufacturing a PTP sheet in which an object is stored in a pocket portion formed in a container film, and a cover film is attached so as to close the pocket portion,
Pocket portion forming means for forming the pocket portion with respect to the container film transported in a strip shape;
Filling means for filling the pocket with the object;
Attaching means for attaching the band-shaped cover film so as to close the pocket portion with respect to the container film filled with the object in the pocket portion,
Separating means for separating the PTP sheet from a strip-shaped body (band-shaped PTP film) in which the cover film is attached to the container film (including punching means for punching in units of sheets);
A PTP packaging machine comprising the inspection device according to the above means 1 or 2 .

By providing the inspection apparatus according to the above means 1 and 2 in the PTP packaging machine as in the above means 3 , there is a merit that defective products including different kinds can be efficiently excluded in the manufacturing process of the PTP sheet. In addition, the PTP packaging machine may include a discharge unit that discharges the PTP sheet that is determined to be defective by the inspection apparatus.

In the means 3 , the inspection apparatus may be arranged in “a post-process in which an object is filled in the pocket portion by the filling means and a pre-process in which the cover film is attached by the attaching means”. In such a case, the inspection can be executed in a state where there is nothing to block the object, and the inspection accuracy can be improved.

  The inspection apparatus may be arranged in a “post-process after the cover film is attached by the attaching means and the pre-process where the PTP sheet is separated by the separating means”. In such a case, the inspection can be executed in a state where the object is not replaced, and the inspection accuracy can be improved.

  Further, the inspection apparatus may be arranged in a “post-process after the PTP sheet is separated by the separating means”. In such a case, it can be confirmed at the final stage whether defective products are mixed.

Means 4. A method for producing a PTP sheet for producing a PTP sheet in which an object is accommodated in a pocket portion formed in a container film and a cover film is attached so as to close the pocket portion,
A pocket portion forming step for forming the pocket portion with respect to the container film transported in a strip shape;
A filling step of filling the pocket with the object;
An attachment step of attaching the band-shaped cover film so as to close the pocket portion, with respect to the container film filled with the object in the pocket portion,
A separation step (including a punching step of punching in units of sheets) for separating the PTP sheet from a strip-shaped body (band-shaped PTP film) in which the cover film is attached to the container film;
And an inspection process for inspecting the mixing of different varieties,
In the inspection step,
An irradiation step of irradiating the object to be continuously conveyed with near infrared light;
A spectroscopic step of allowing the reflected light reflected from the object irradiated with the near-infrared light to enter a predetermined spectroscopic means through a predetermined slit and split the light;
An imaging step (exposure step) for capturing a spectral image of the reflected reflected light;
A spectral data acquisition step for acquiring spectral data based on the spectral image;
An analysis step of detecting different varieties by performing a predetermined analysis process (for example, principal component analysis) based on the spectrum data,
A method of manufacturing a PTP sheet, wherein the imaging step (exposure step) is executed in an imaging cycle that satisfies the following relational expressions (1), (2), and (3) .

R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes.

Means 5. A method for producing a PTP sheet for producing a PTP sheet in which an object is accommodated in a pocket portion formed in a container film and a cover film is attached so as to close the pocket portion,
A pocket portion forming step for forming the pocket portion with respect to the container film transported in a strip shape;
A filling step of filling the pocket with the object;
An attachment step of attaching the band-shaped cover film so as to close the pocket portion, with respect to the container film filled with the object in the pocket portion,
A separation step of separating the PTP sheet from a belt-like body in which the cover film is attached to the container film;
And an inspection process for inspecting the mixing of different varieties,
In the inspection step,
An irradiation step of irradiating the object to be continuously conveyed with near infrared light;
A spectroscopic step of spectroscopically reflecting the reflected light reflected from the object irradiated with the near-infrared light into a predetermined spectroscopic means via an optical lens composed of a bilateral telecentric lens and a predetermined slit;
An imaging step of capturing a spectral image of the reflected reflected light;
A spectral data acquisition step for acquiring spectral data based on the spectral image;
An analysis step of detecting different varieties by performing a predetermined analysis process based on the spectrum data,
A method of manufacturing a PTP sheet, wherein the imaging step is executed in an imaging cycle that satisfies the following relational expressions (1), (2), and (3) .
R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes.
According to the means 4 and 5, the same effect as the means 3 is obtained. In the means 4 and 5, the inspection process may be performed as “a post process of the filling process and a pre process of the attachment process”. In such a case, the inspection can be executed in a state where there is nothing to block the object, and the inspection accuracy can be improved.

  Moreover, it is good also as a structure which performs the said test | inspection process in "the post process of an attachment process, and the pre process of a separation process." In such a case, the inspection can be executed in a state where the object is not replaced, and the inspection accuracy can be improved.

  Moreover, it is good also as a structure which performs the said test | inspection process in "the post process of a cutting process." In such a case, it can be confirmed at the final stage whether defective products are mixed.

(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 perspective view which shows typically the arrangement configuration of an inspection apparatus. It is a schematic diagram which shows schematic structure of an imaging device. It is a flowchart which shows a spectrum data acquisition routine. It is a flowchart which shows a test | inspection routine. It is explanatory drawing for demonstrating the relationship between an imaging cycle and the magnitude | size of a tablet. It is explanatory drawing for demonstrating the relationship between a conveyance direction imaging range, a tablet, etc. FIG. It is a schematic diagram which shows a spectrum image. It is explanatory drawing for demonstrating the relationship between a conveyance direction imaging range and a spectrum image. It is explanatory drawing for demonstrating the relationship between the target object and imaging range in the conventional inspection apparatus.

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

  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. And in the state which the container film 3 was heated with the heating apparatus 15 and this container film 3 became comparatively flexible, the several pocket part 2 is shape | molded by the pocket part formation apparatus 16 in the predetermined position of the container film 3 ( Pocket part forming step). 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 the tablet 5 (filling step).

  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 apparatus 22 is an inspection apparatus that performs inspection using spectroscopic analysis, and is for inspecting mixing of different varieties. Details of the inspection device 22 will be described later.

  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. (Installation process). 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 sheet punching means (cutting means) for punching 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 (cutting process). 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 detail below with reference to the drawings. 4 is a block diagram showing an electrical configuration of the inspection apparatus 22, and FIG. 5 is a perspective view schematically showing an arrangement configuration of the inspection apparatus 22. As shown in FIG.

  As shown in FIGS. 4 and 5, the inspection device 22 performs various controls, image processing, arithmetic processing, and the like in the inspection device 22 such as the illumination device 52, the imaging device 53, and drive control of the illumination device 52 and the imaging device 53. And a control processing device 54 to be implemented.

  The illumination device 52 and the imaging device 53 are disposed on the opening side of the pocket portion 2 of the container film 3. That is, in this embodiment, a different kind mixing inspection is performed from the pocket part 2 opening side of the container film 3 in the stage before the cover film 4 is attached.

  The illumination device 52 is a well-known device configured to be able to irradiate near-infrared light, and constitutes an irradiation unit in the present embodiment. The illuminating device 52 is arrange | positioned so that near infrared light can be irradiated from diagonally upward toward the predetermined area | region on the container film 3 conveyed continuously.

  In the illumination device 52 according to the present embodiment, a halogen lamp is employed as a light source capable of emitting near-infrared light having a continuous spectrum (for example, a near-infrared region having a wavelength of 700 to 2500 nm). In addition, a deuterium discharge tube, a tungsten lamp, a xenon lamp, or the like can be used as the light source.

  As shown in FIG. 6, the imaging device 53 includes an optical lens 61, a two-dimensional spectroscope 62 as a spectral unit, and a camera 63 as an imaging unit.

  The optical lens 61 includes a plurality of lenses (not shown) and the like, and is configured to be able to collimate incident light. The optical lens 61 is set so that incident light can be imaged at a position of a slit 62a of a two-dimensional spectroscope 62 described later. Here, for the sake of convenience, an example in which a double-sided telecentric lens is adopted as the optical lens 61 is shown, but an image-side telecentric lens may naturally be used.

  The two-dimensional spectroscope 62 includes a slit 62a, an incident side lens 62b, a spectroscopic unit 62c, and an output side lens 62d. The spectroscopic unit 62c includes an incident side prism 62ca, a transmissive diffraction grating 62cb, and an output side prism 62cc.

  Under such a configuration, the light that has passed through the slit 62a is collimated by the incident side lens 62b, and then is split by the spectroscopic unit 62c, and is output to the imaging element 63a of the camera 63, which will be described later, by the output side lens 62d. The image is formed as (spectral spectrum).

  The slit 62a is formed in an elongated and substantially rectangular shape (line shape), its width direction (short direction) is disposed along the film transport direction (X direction) of the container film 3, and its longitudinal direction is the transport direction. It arrange | positions along the film width direction (Y direction) of the container film 3 orthogonal to a direction. As a result, the two-dimensional spectroscope 62 separates the incident light in the width direction of the slit 62a, that is, in the film transport direction (X direction).

  The camera 63 includes an image sensor 63a having a light receiving surface on which a plurality of light receiving elements are two-dimensionally arranged. In the present embodiment, a CCD area sensor having sufficient sensitivity with respect to a wavelength range of, for example, a wavelength of 900 to 1700 nm in the near infrared region is employed as the image sensor 63a. Of course, the imaging device is not limited to this, and other sensors having sensitivity in the near infrared region may be adopted. For example, a CMOS sensor, an MCT (HgCdTe) sensor, or the like may be employed.

  The visual field region of the imaging device 53 is a linear region extending along the film width direction (Y direction) and includes at least the entire region of the container film 3 in the film width direction (see the two-dot chain line portion in FIG. 5). ). On the other hand, the visual field region of the imaging device 53 in the film transport direction (X direction) is a region corresponding to the width W (see FIG. 9) of the slit 62a. That is, this is a region where the light passing through the slit 62a forms an image on the light receiving surface of the image sensor 63a.

  Then, each light receiving element of the imaging element 63a receives the spectrum (light of each wavelength) of the reflected light reflected at each position in the film width direction (Y direction) of the container film 3. Then, a signal corresponding to the intensity of light received by each light receiving element is output to the control processing device 54.

  The control processing device 54 is an input device 72 as “input means” composed of a CPU and an input / output interface 71 (hereinafter referred to as “CPU etc. 71”), a keyboard, a mouse, a touch panel, etc. A display device 73 as a “display unit” having a display screen such as a CRT or a liquid crystal, an image data storage device 74 for storing various image data, an arithmetic result storage device 75 for storing various arithmetic results, A setting data storage device 76 for storing various kinds of information in advance is provided. The devices 72 to 76 are electrically connected to the CPU 71 and the like.

  The CPU 71 is connected to the PTP packaging machine 10 so that various signals can be transmitted and received. Thereby, for example, the defective sheet discharge mechanism of the PTP packaging machine 10 can be controlled.

  The image data storage device 74 includes spectral image data captured by the imaging device 53, spectral image data acquired based on the spectral image data, binarized image data after binarization processing, and after differential processing. This is for storing differential image data and the like.

  The calculation result storage device 75 stores 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 display device 73.

  The setting data storage device 76 stores, for example, loading vectors and determination ranges used for principal component analysis, and shapes and dimensions of the PTP sheet 1, the pocket portion 2, and the tablet 5.

  Next, the procedure of the different product mixture inspection (inspection process) performed by the inspection apparatus 22 will be described.

  First, a spectrum data acquisition routine for acquiring spectrum data to be analyzed will be described with reference to the flowchart of FIG. This routine is a process that is repeatedly executed every time the container film 3 is conveyed by a predetermined amount.

  In step S01, first, the control processing device 54 irradiates near-infrared light from the illumination device 52 to the continuously transported container film 3 (tablet 5) (irradiation process), while the imaging processing (exposure processing) by the imaging device 53 is performed. ).

  Here, the control processing device 54 drives and controls the imaging device 53 based on a signal from an encoder (not shown) provided in the PTP packaging machine 10, and spectral image data captured by the imaging device 53 is stored in an image data storage device 74. Into. The processing function of the control processing device 54 that controls the timing constitutes the imaging timing control means in the present embodiment.

  More specifically, the imaging process is executed in an imaging cycle T that satisfies the following relational expressions (1) and (2) (see FIG. 9). FIG. 9 is an explanatory diagram for explaining the relationship between the imaging cycle T and the size of the tablet 5.

R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
However,
V: Conveying speed of container film 3 (tablet 5),
R: Diameter of tablet 5
W: width of the slit 62a (“W” is the width of the slit 62a when the optical lens 61 is a double-sided telecentric lens; otherwise, for example (in the case of an image side telecentric lens), the slit in the transport direction ) Corresponding to the width of the tablet 5, that is, the width in consideration of the enlargement / reduction by the optical lens 61.
L ₀ : transport amount of the container film 3 (tablet 5) transported during one imaging cycle,
_Li : A transport amount of the container film 3 (tablet 5) transported during the interval between the image capturing process and the image capturing process.

The interval period referred to here is a period for reading image data. That is, the imaging cycle T can be represented by the total time of the exposure period t _e that is the execution period of the imaging process and the interval period t _i (T = t _e + t _i ).

Therefore, as shown in FIG. 9, the transport amount L ₀ of the container film 3 transported during one imaging cycle period T is equal to the transport amount L _e of the container film 3 transported during the exposure period t _e . It can be represented by the total transport amount L _i of the container film 3 transported during the interval period t _i (L ₀ = L _e + L _i ).

Further, step S01, i.e. the conveying direction imaging range D to be imaged in one imaging process (exposure period t _e) includes a conveying distance L _e of the container film 3 to be conveyed during the exposure period t _e, the slits 62a It can be expressed as the sum of the width W (D = L _e + W).

And among the near-infrared light irradiated toward the container film 3 from the illuminating device 52, the reflected light reflected in the conveyance direction imaging range D during the imaging process execution period (exposure period t _e ) in step S01 is reflected. Incident on the imaging device 53.

The reflected light incident on the imaging device 53 is dispersed by the two-dimensional spectroscope 62 (spectral process) and captured as a spectral image (spectral spectrum) by the imaging element 63a of the camera 63 (imaging process). In addition, since the container film 3 (tablet 5) is continuously conveyed during the execution period (exposure period t _e ) of the imaging process, the averaged spectral spectrum of the conveyance direction imaging range D is imaged here. Become.

The spectral image data captured by the imaging device 53 is output to the control processing device 54 during the interval period t _i and stored in the image data storage device 74.

  When the spectral image data is acquired, the control processing device 54 starts the data generation process in step S02.

  In the data generation process, spectrum data is generated based on the spectral image data acquired in step S01. When the spectrum data is generated, it is stored in the image data storage device 74, and this routine is terminated once. This process corresponds to the spectrum data acquisition process in the present embodiment, and the spectrum data acquisition means in the present embodiment is configured by the processing function of the control processing device 54 that executes the process.

  As shown in FIGS. 9 and 10, every time the container film 3 (tablet 5) is transported by a predetermined amount, the transport direction imaging range D is intermittently relatively moved, and the spectrum data acquisition routine is repeated. As a result, the image data storage device 74 sequentially stores the spectral data corresponding to the imaging direction D in the transport direction together with the position information in the film width direction in time series. As a result, a two-dimensional spectrum image G having spectrum data for each pixel is generated (see FIG. 11).

  Here, the spectrum image G in the present embodiment will be described. As shown in FIG. 11, the spectrum image G is image data in which a plurality of pixels Ga are two-dimensionally arranged. Each pixel Ga includes spectral data (data indicating spectral intensities at a plurality of wavelengths or wavelength bands).

  And if the spectrum image G of the range (refer the dashed-two dotted line part of FIG. 11) equivalent to the one PTP sheet 1 used as a test object is acquired, the control processing apparatus 54 will perform a test routine.

  Next, the inspection routine will be described with reference to the flowchart of FIG. The inspection routine is repeatedly performed every time a spectrum image G in a range corresponding to one PTP sheet 1 is acquired.

  First, in step S11, the control processing device 54 extracts a pixel corresponding to the tablet 5 from each pixel Ga of the spectrum image G, that is, a pixel (target pixel) Gb to be analyzed.

  In the present embodiment, for example, it is determined whether the intensity data of a predetermined wavelength in the spectrum data of each pixel Ga is equal to or greater than a predetermined threshold value, and the binarization process is performed on the spectrum image G. Then, the target pixel Gb is extracted based on the obtained binarized image data (see FIGS. 11 and 12).

  As shown in FIG. 12, in this embodiment, a pixel Ga including data obtained by imaging only the range of the tablet 5 without being affected by the background is extracted as the target pixel Gb. FIG. 12 is an explanatory diagram for explaining the relationship between the conveyance direction imaging range D and the spectrum image G. In FIGS. 11 and 12, the pixel extracted as the target pixel Gb is indicated by hatching.

  The pixel extraction method is not limited to this, and other methods may be adopted. For example, the integrated value of spectrum data may be calculated for each pixel Ga, and the target pixel Gb may be extracted by determining whether or not the value is equal to or greater than a predetermined threshold.

  Next, in step S12, the control processing device 54 performs a grouping process on the target pixel Gb obtained in step S11. In the present embodiment, for example, all adjacent target pixels Gb are set as one group.

  The grouping method is not limited to this, and other methods may be adopted. For example, a pixel included in a predetermined range centered on a specific pixel with respect to a specific pixel may be determined to be in the same group as the specific pixel.

  The target pixels Gb grouped into one are handled as the target pixels Gb related to the same tablet 5 (see FIGS. 11 and 12). In FIGS. 11 and 12, the grouped target pixels Gb are surrounded by a thick frame.

  Next, in step S13, the control processing device 54 calculates the spectrum data related to the tablet 5 corresponding to the group based on the spectrum data of the target pixel Gb grouped in step S12.

  In the present embodiment, all the spectrum data of the grouped target pixels Gb are used to obtain an average value, which is calculated as the spectrum data related to the tablet 5. Not limited to this, one or more target pixels Gb may be extracted from the grouped target pixels Gb, and the spectrum data of the target pixels Gb may be calculated as the spectrum data related to the tablet 5. Moreover, you may make it perform a differentiation process etc. suitably.

  Next, the control processing apparatus 54 performs an analysis process in step S14. Such processing corresponds to the analysis step in the present embodiment, and the analysis means in the present embodiment is configured by the function of the control processing device 54 that executes such processing.

  In the present embodiment, principal component analysis (PCA) is performed on the spectrum data of the tablet 5 obtained in step S13 using a loading vector acquired in advance. More specifically, the principal component score is calculated by calculating the loading vector and the spectrum data of the tablet 5.

  Subsequently, in step S15, the control processing device 54 performs determination processing for determining whether the target tablet 5 is a non-defective product (same product type) or a defective product (different product type). More specifically, the principal component score calculated in step S14 is plotted on a PCA diagram. ).

  Note that the series of processing in step S15 is performed for all tablets 5 on the PTP sheet 1, and when there is no “bad” tablet 5, the PTP sheet 1 is treated as a non-defective product. Is determined (step S16), and this routine is terminated. On the other hand, if there is at least one tablet 5 that is “defective”, the PTP sheet 1 is determined to be defective (step S17), and this routine is terminated. These inspection results are output to the display device 73 and the PTP packaging machine 10 (including the defective sheet discharge mechanism).

  As described above in detail, according to the present embodiment, since the imaging process is performed while transporting the tablet 5 without stopping, the transport direction imaging range D that can be imaged by one imaging process is set to the slit width W or more. And the number of times of imaging for acquiring spectral data necessary for spectroscopic analysis can be reduced.

  In addition, in this embodiment, since the imaging process is performed in the imaging cycle T, the spectrum of the tablet 5 is imaged at least once without being affected by the background regardless of the position of the tablet 5 in the pocket 2. be able to.

  Further, in the present embodiment, since the imaging process is performed while the tablet 5 is being conveyed, the spectrum for each measurement point is integrated, and the predetermined imaging range is averaged without performing an arithmetic process afterwards. A spectrum can be acquired.

  As a result, it is possible to increase the speed of inspection for mixing different types using spectroscopic analysis.

  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 object is the tablet 5 is specified, but the type, shape, etc. of the object are not particularly limited, and examples thereof include capsules, supplements, foods, and the like. May be. Tablets include solid preparations such as plain tablets and sugar-coated tablets.

  (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-described embodiment, and include various arrangements and numbers including, for example, a type having three rows and 12 pocket portions. A PTP sheet can be employed.

  (D) In the above-described embodiment, a configuration in which a different product mixture inspection is performed by the inspection device 22 in the post-process in which the tablet 5 is filled in the pocket portion 2 and the pre-process in which the cover film 4 is attached to the container film 3 is performed. It has become.

  For example, in the post-process where the cover film 4 is attached to the container film 3 and the pre-process where the PTP sheet 1 is punched from the PTP film 6, the inspection apparatus 22 performs the inspection from the container film 3 side of the PTP film 6. It is good also as a structure by which a different kind mixing inspection is performed.

  Further, in the post-process after the PTP sheet 1 is punched out from the PTP film 6, a different product mixture inspection by the inspection device 22 may be performed from the container film 3 side of the PTP sheet 1 conveyed by the take-out conveyor 39.

  (E) The configuration of the illumination device 52 and the imaging device 53 is not limited to the above embodiment. For example, instead of the two-dimensional spectroscope 62, a reflection type diffraction grating, a prism, or the like may be adopted as the spectroscopic means.

  (F) In the above embodiment, the spectral data is analyzed by principal component analysis (PCA). However, the present invention is not limited to this, and other known methods such as PLS regression analysis may be used. Good.

  (G) In the above embodiment, the inspection device 22 is provided in the PTP packaging machine 10 (inline). Instead, the PTP sheet 1 is taken off-line separately from the PTP packaging machine 10. It is good also as a structure provided with the test | inspection apparatus 22 as an apparatus to test | inspect. In such a case, the inspection apparatus 22 may be provided with a transport unit that can transport the PTP sheet 1.

In (h) the above-described embodiment, the exposure period t _e is the execution period of imaging processing, especially is not mentioned, the container film 3 2 pixels of the image pickup element 63a of the conveyance amount (tablet 5) of at least a camera 63 It is preferable to have a configuration in which the imaging process is continuously executed during the above.

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 apparatus, 53 ... Imaging apparatus, 54 ... Control processing apparatus , 62 ... two-dimensional spectrometer, 62a ... slit, 63 ... camera, 63a ... imaging element, V ... container transport speed of the film, the R ... tablet diameter, W ... slit width, L ₀ ... during one imaging cycle The transport amount of the container film transported to the surface, L _i .

Claims (5)

An inspection apparatus used in manufacturing a PTP sheet in which an object is stored in a pocket portion formed in a container film, and a cover film is attached so as to close the pocket portion,
Irradiating means capable of irradiating near-infrared light to the object to be continuously conveyed;
A spectroscopic means capable of spectroscopically entering the reflected light reflected from the object irradiated with the near infrared light through a predetermined slit;
An imaging unit capable of capturing a spectral image of the reflected light spectrally separated by the spectral unit;
Spectral data acquisition means capable of acquiring spectral data based on the spectral image;
Analysis means capable of detecting different varieties by performing a predetermined analysis process based on the spectrum data;
An inspection apparatus comprising: an imaging timing control unit capable of executing an imaging process by the imaging unit in an imaging cycle that satisfies the following relational expressions (1), (2), and (3):
R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes. An inspection apparatus used in manufacturing a PTP sheet in which an object is stored in a pocket portion formed in a container film, and a cover film is attached so as to close the pocket portion,
Irradiating means capable of irradiating near-infrared light to the object to be continuously conveyed;
A reflected light reflected from the object irradiated with the near-infrared light, an optical lens made of a telecentric lens on both sides, and a spectroscopic means capable of spectroscopically entering through a predetermined slit;
An imaging unit capable of capturing a spectral image of the reflected light spectrally separated by the spectral unit;
Spectral data acquisition means capable of acquiring spectral data based on the spectral image;
Analysis means capable of detecting different varieties by performing a predetermined analysis process based on the spectrum data;
An inspection apparatus comprising: an imaging timing control unit capable of executing an imaging process by the imaging unit in an imaging cycle that satisfies the following relational expressions (1), (2), and (3):
R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes. A PTP wrapping machine for manufacturing a PTP sheet in which an object is stored in a pocket portion formed in a container film, and a cover film is attached so as to close the pocket portion,
Pocket portion forming means for forming the pocket portion with respect to the container film transported in a strip shape;
Filling means for filling the pocket with the object;
Attaching means for attaching the band-shaped cover film so as to close the pocket portion with respect to the container film filled with the object in the pocket portion,
A separating means for separating the PTP sheet from a belt-like body in which the cover film is attached to the container film;
A PTP packaging machine comprising the inspection apparatus according to claim 1. A method for producing a PTP sheet for producing a PTP sheet in which an object is accommodated in a pocket portion formed in a container film and a cover film is attached so as to close the pocket portion,
A pocket portion forming step for forming the pocket portion with respect to the container film transported in a strip shape;
A filling step of filling the pocket with the object;
An attachment step of attaching the band-shaped cover film so as to close the pocket portion, with respect to the container film filled with the object in the pocket portion,
A separation step of separating the PTP sheet from a belt-like body in which the cover film is attached to the container film;
And an inspection process for inspecting the mixing of different varieties,
In the inspection step,
An irradiation step of irradiating the object to be continuously conveyed with near infrared light;
A spectroscopic step of allowing the reflected light reflected from the object irradiated with the near-infrared light to enter a predetermined spectroscopic means through a predetermined slit and split the light;
An imaging step of capturing a spectral image of the reflected reflected light;
A spectral data acquisition step for acquiring spectral data based on the spectral image;
An analysis step of detecting different varieties by performing a predetermined analysis process based on the spectrum data,
A method of manufacturing a PTP sheet, wherein the imaging step is executed in an imaging cycle that satisfies the following relational expressions (1), (2), and (3) .
R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes. A method for producing a PTP sheet for producing a PTP sheet in which an object is accommodated in a pocket portion formed in a container film and a cover film is attached so as to close the pocket portion,
A pocket portion forming step for forming the pocket portion with respect to the container film transported in a strip shape;
A filling step of filling the pocket with the object;
An attachment step of attaching the band-shaped cover film so as to close the pocket portion, with respect to the container film filled with the object in the pocket portion,
A separation step of separating the PTP sheet from a belt-like body in which the cover film is attached to the container film;
And an inspection process for inspecting the mixing of different varieties,
In the inspection step,
An irradiation step of irradiating the object to be continuously conveyed with near infrared light;
A spectroscopic step of spectroscopically reflecting the reflected light reflected from the object irradiated with the near-infrared light into a predetermined spectroscopic means via an optical lens composed of a bilateral telecentric lens and a predetermined slit;
An imaging step of capturing a spectral image of the reflected reflected light;
A spectral data acquisition step for acquiring spectral data based on the spectral image;
An analysis step of detecting different varieties by performing a predetermined analysis process based on the spectrum data,
A method of manufacturing a PTP sheet, wherein the imaging step is executed in an imaging cycle that satisfies the following relational expressions (1), (2), and (3) .
R ≧ 2 × L ₀ + W−L _i (1)
L ₀ = T × V (2)
L ₀ −L _i ≧ 2 pixels of the image sensor of the imaging means (3)
However,
T: imaging cycle,
V: object conveyance speed,
R: length of the object in the conveying direction,
W: the width on the object corresponding to the width of the slit in the transport direction,
L ₀ : transport amount of the object transported during one imaging cycle,
L _i : A carry amount of the object carried during the interval period between the imaging processes.

Images