JP6752986B1 - Tube container inspection device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a tube container inspection device provided with a simple transport mechanism and appropriately inspecting the inside and outside of a tube container. SOLUTION: A tube container inspection device holds a flexible tube container on its side in a transport mechanism, rotates it by a rotation mechanism, and takes a picture of the tube container with a first camera having an imaging system having a deep depth of field. Meander correction is applied to the internal image. The control unit of the tube container inspection device detects an edge in which the difference between adjacent pixels is equal to or greater than a predetermined threshold value in the meander-corrected image inside the container, and the shape is based on the contour surrounded by the edge. Is identified and extracted as a defective part. An image of the inside of the container in which the defective portion is emphasized is displayed by the defect enhancing processing unit, and the tube container having the defective portion is excluded from the transport mechanism by the defective product eliminating unit. [Selection diagram] Fig. 1

Description

An embodiment of the present invention relates to a tube container inspection device that detects foreign matter, scratches, and stains adhering to a tube container.

Generally, a paste-like content such as toothpaste is used by being filled in a tube container which is a soft tubular container. Usually, the production of the tube container and the filling of the contents in the tube container are performed in different places (factories). Before shipping the unfilled tube container and optionally before filling the contents, foreign matter that has entered the inside of the tube container by visual inspection by the operator or confirmation of images taken from multiple directions by multiple cameras The presence or absence and the presence or absence of scratches and dirt on the outer and inner surfaces of the tube container are inspected.

Japanese Unexamined Patent Publication No. 04-194732

Since the above-mentioned entry of foreign matter or the like into the tube container is a defect that occurs after being manufactured in a normal tube container, 100% inspection of the tube container is preferable. For visual inspections in which the tube container is viewed directly, it is desired to reduce the cost of securing the number of inspection workers, improve the efficiency of the inspection, and prevent human error such as oversight. As an inspection method for realizing these, there is an inspection method in which 100% inspection of the tube container is performed by confirming an image of the tube container.

For example, there is an inspection device that inspects 100% of manufactured tube containers by checking images of tube containers taken by a plurality of cameras. In a mass-produced tube container manufacturing line, it may not be possible to arrange the above-mentioned inspection device on the main transport line so as to interrupt it due to the installation space of the manufacturing device and the manufacturing process. In such a case, for example, as disclosed in Patent Document 1, a turret-type inspection transport line that branches off from the main transport line and bypasses it is constructed. A plurality of cameras and the like are arranged along the branched inspection transfer line, and the tube container judged to be non-defective by the inspection is returned to the original main transfer line. In the case of an inspection device using a plurality of cameras, several cameras are arranged at different positions, such as a camera that photographs the inner surface of the tube container, the inner surface of the shoulder, and the inside of the nozzle tip, and a camera that photographs the inner surface of the body of the tube container. The inspection device is large and has a complicated structure because it requires a space to be used and includes a transport mechanism for a tube container.
Therefore, an object of the present invention is to provide a tube container inspection device provided with a simple transport mechanism and performing appropriate inspections on the inside and outside of the tube container.

In order to achieve the above object, the tube container inspection apparatus according to the embodiment has a holding having a roller pair having a shoulder portion at one end and a flexible tube container having an open end end rotatably held in a sideways state. A unit, a transport mechanism provided with a plurality of the holding portions and having an infinite trajectory forming a linear transport path, and a belt member arranged in the transport mechanism or adjacent to the transport mechanism, and rotating. A rotation mechanism that rotates the roller pair by sliding by the belt member to rotate the tube container placed on the holding portion, an extension surface of the main surface of the photographing lens, and an imaging surface of the image pickup element. The photographing lens and the imaging element are arranged so that the extended surfaces intersect at one intersection, and the container is opened from the other end opening on the focusing surface intersecting the intersection of the tube container that rotates in the sideways state. An edge in which the difference between adjacent pixels is equal to or greater than a predetermined threshold value with respect to an image pickup unit having a first camera for photographing the inside and an image of the inside of the tube container photographed by the first camera. The meandering part is generated in the image of the opening at the other end of the rotating tube container taken by the first camera and the control unit that detects and extracts the edge as a defect part. It includes a meandering correction unit that linearly aligns the portions, and an image processing unit that includes a defect enhancement processing unit that enhances an image including coloring in order to distinguish the defect portion from other image regions .

According to the present invention, it is possible to provide a tube container inspection device provided with a simple transfer mechanism and performing proper inspection on the inside and outside of the tube container.

FIG. 1 is a diagram showing a conceptual overall configuration example of a tube container inspection device including a transfer line according to the first embodiment. FIG. 2 is a block diagram showing a configuration example of the tube container inspection device of the first embodiment. FIG. 3 is a diagram showing a configuration example of a transport mechanism of a tube container inspection device including a tube container rotation mechanism. FIG. 4 is a diagram showing an arrangement example of a camera for photographing the inner peripheral surface of the tube container. FIG. 5 is a diagram showing an example of an developed image of the inside of the tube container taken by the tube container inspection device of the first embodiment. FIG. 6 is a diagram showing an example of an image obtained by applying meandering correction to an developed image of the inside of the tube container taken by the tube container inspection device of the first embodiment. FIG. 7 is a diagram showing a conceptual overall configuration example of the tube container inspection device including the transfer line according to the second embodiment. FIG. 8 is a block diagram showing a configuration example of the tube container inspection device of the second embodiment. FIG. 9 is a diagram showing an arrangement example of a camera for photographing the outer peripheral surface of the tube container.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[First Embodiment]
FIG. 1 is a diagram showing a conceptual overall configuration example of a tube container inspection device including a transfer line according to the first embodiment. FIG. 2 is a block diagram showing a configuration example of a tube container inspection device. FIG. 3 is a diagram showing a configuration example of a transport mechanism of a tube container inspection device including a tube container rotation mechanism. FIG. 4 is a diagram showing an arrangement example of a camera for photographing the inner peripheral surface of the tube container. FIG. 5 is a diagram showing an example of an image of the inside of the tube container taken. FIG. 6 is a diagram showing an example of an image obtained by applying meandering correction to the photographed image of the inside of the tube container.

The tube container inspection device 1 of the first embodiment targets a tube container which is a flexible cylindrical container immediately before shipping and packing or immediately before filling the contents, and the inside of the tube container 2 photographed by the photographing unit 20. This is an inspection device that detects foreign matter that has entered the inside of the tube container 2 and scratches and stains that have occurred on the inner peripheral surface 2f from the image of. In the following description, foreign matter, scratches and dirt are referred to as defects, and the presence of foreign matter, scratches and dirt is referred to as defects.
The tube container inspection device 1 according to the present embodiment is arranged in the inspection step at the final end of the tube container production line 100, and inspects the inside of the tube container for defects before shipment.

The tube container 2 to be inspected has a hollow cylindrical shape, and is, for example, a tube container made of a thin metal plate, a resin, or a resin on which a thin metal film (laminated film) is laminated. This embodiment is suitable for inspection of a soft resin tube container or a soft tube container such as a laminated tube container.

As shown in FIG. 4, in the tube container 2, a narrowed shoulder portion 2b and a spout portion 2d provided at the tip of the shoulder portion 2b are formed at one end of a tubular body portion 2g. The spout portion 2d is formed in a convex shape having an opening of the spout 2c for squeezing out the contents, and a cap of another member is detachably attached.

The inside of the tube container 2 at the time of inspection in the present embodiment is empty before filling the contents, and the opening 2e at the other end of the body 2g of the tube container 2 is in an open state. After the contents are filled in the tube container 2, the opening 2e is crushed or folded and sealed by thermocompression bonding or pressure bonding. Although the tube container 2 has a circular cross-sectional shape, the entire inside of the container can be photographed with the tube container 2 rotated by a line scan camera (first camera 22) described later. If possible, the cross-sectional shape is not particularly limited. Further, the inspection target of the present embodiment is not limited to the tube container 2, and can be applied as long as it can be rotated and has a size that fits within the shooting range of the camera. For example, an elongated cup (bottomed) or a box. Alternatively, it may be a cylindrical tube or the like. In the present embodiment described below, the tube container 2 to be inspected will be described by taking a soft resin tube container or a laminated tube container as an example.

The tube container inspection device 1 shown in FIG. 1 includes a transport mechanism 3 using a first conveyor 21 as a transport means for the tube container 2, and an inspection unit 4 including a photographing unit 20 including a first camera 22 and an illumination unit 19. The image processing unit 5 that performs image processing described later on the image captured by the inspection unit 4, the rotation mechanism 6 that rotates the tube container 2 at the time of photographing, and the motor drive control unit 7 that drives and controls the transport mechanism 3 and the rotation mechanism 6. A defective product exclusion unit 8 that eliminates the tube container 2 determined to have a defect into the defective product storage box 29, a control unit 9 that controls the entire device including the defect determination described later, and an inspection unit for carrying out the inspection. A storage unit 10 that stores data such as programs and judgment criteria and judgment results, a display unit 11 that displays input information, inspection status, and inspection results, and a tube container 2 immediately before inspection to remove foreign matter by ejecting compressed air. A foreign matter removing unit 12 is provided.

First, the transfer mechanism 3 constructs a linear transfer path by using the first conveyor 21 as a transfer means, in which a pair of parallel track-shaped conveyor chains 33 are hung on two sprockets 31 and 32. ing.
As shown in FIGS. 1 and 3, the first conveyor 21 is composed of a drive sprocket 31, a driven sprocket 32, and two conveyor chains 33. In the first conveyor 21, the conveyor chain 33 is hung on both side surfaces of the drive sprocket 31 and the driven sprocket 32 which are rotatably provided at both ends of the conveyor base portion 30. A first motor 23 is connected to the drive sprocket 31 via a gear mechanism (not shown). The first conveyor 21 is rotationally driven, for example, clockwise by the first motor 23. Of course, the transport means is not limited to the chain conveyor. For example, the tube container holding portion 15 described later may be attached to each of a plurality of flat small rectangular plates, and these rectangular plates may be bent by a hinge or the like to have an endless track structure in which they are connected in an annular shape. In the case of this configuration, the rotation mechanism 6 is arranged beside the small rectangular plate and comes into contact with the rotation shaft of the extended roller 15a to rotate the roller 15a. It is also possible to use a wire instead of the chain.

The plurality of tube container holding portions 15 are attached to the conveyor chain 33 at intervals in the longitudinal direction which is the transport direction. The tube container holding portion 15 is a support portion that rotatably supports both ends of a pair of small rectangular plates a on which the tube container 2 is placed and rotated, and a roller 15a, and is attached so as to hang over two rows of conveyor chains 33. It is composed of 15b. The support portion 15b is attached to the conveyor chain 33 at positions facing each other at intervals by using an attachment (not shown).

The tube containers 2 to be inspected, which are continuously supplied from the production line 100 in the first stage of the manufacturing process, are sequentially placed sideways on the rollers 15a of the tube container holding portion 15. The roller 15a has a roller length equal to or larger than the length of the body portion 2g of the tube container 2. At least these rollers 15a are not easily charged with static electricity, and are formed of, for example, a metal material. It is preferable that the surface of the roller 15a of the tube container holding portion 15 is subjected to anti-slip processing so that the rotational force is efficiently transmitted to the tube container 2. In addition to the surface processing of the roller 15a, for example, a conductive resin cap and a rubber cap may be coated.

The distance between the pair of rollers 15a may be set based on the diameter of the body 2g of the placed tube container 2 so that the rotated tube container 2 does not come off from the rollers 15a. Further, the interval between the tube container holding portions 15 on the first conveyor 21 may be an arbitrary distance according to the number of inspection processes per hour and the device specifications. Further, the tube container holding portion 15 may reduce the frictional resistance by fitting a bearing between the rotating shaft of each roller 15a and the supporting portion 15b.

The motor drive control unit 7 drives the first motor 23 to rotate the drive sprocket 31, so that the conveyor chain 33 is rotated. The tube container 2 is conveyed by moving the tube container holding portion 15 according to the rotation of the conveyor chain 33. The first conveyor 21 is intermittently moved at a predetermined pitch (interval between the tube container holding portions 15) by the first motor 23 controlled by the motor drive control unit 7. The motor drive control unit 7 controls the first motor 23 to stop the tube container 2 at the photographing position (that is, the focusing position) P1 defined by the first camera 22. For example, the motor drive control unit 7 uses a mechanical sensor or an optical sensor to control the first motor 23 so that the tube container holding unit 15 on the conveyor chain 33 stops at an accurate photographing position. Further, as the first motor 23, for example, a stepping motor or the like, which can obtain an accurate moving distance for each pitch, may be used. If a stepping motor is used, it is possible to stop at the imaging position by open-loop control using a pulse signal.

As shown in FIG. 2, the inspection unit 4 includes a photographing unit 20 and a lighting unit 19. In this example, since the image is taken only inside the tube container 2, it can be performed by the first camera 22 including one line scan camera. As shown in FIGS. 1, 3 and 4, the first camera 22 photographs the entire inside of the tube container 2 held by the tube container holding portion 15 with the focusing position at the photographing position P1. It is placed at a position that matches the angle of view).

As shown in FIGS. 3 and 4, the first camera 22 is arranged diagonally behind the opening 2e of the tube container 2 so that the inner peripheral surface of the tube container 2 is in the focusing position (photographing position P1). , The inner peripheral surface of the tube container 2 is photographed from the opening 2e of the tube container 2 with the spout 2c as the angle of view (inner peripheral surface imaging range). The first camera 22 is, for example, a line scan camera in which image pickup elements are arranged in a row. This line scan camera is useful for a long subject because the shooting range in the row direction of the imaging elements is defined, but the shooting range in the direction intersecting the row directions is not limited. That is, by taking a picture while moving the camera or the subject, it is possible to obtain an image in a shooting range having a desired length.

As shown in FIG. 4, the first camera 22 has a configuration in which a deep depth of field can be obtained by using the principle of Scheimpflug in arranging the photographing lens (objective lens) 22a and the image pickup element 22b. That is, the surface on which the main surface of the photographing lens 22a is extended and the surface on which the imaging surface of the image pickup element 22b is extended are arranged so as to intersect at one intersection. The first camera 22 focuses on the entire surface of the surface that intersects the intersection G1. Therefore, the imaging position P1 of the first camera 22 is set so that the intersection G1 intersects the surface extending the inner peripheral surface 2f of the tube container 2 to be imaged. With this arrangement, it is possible to obtain an image in focus from the opening 2e of the tube container 2 to the inner peripheral surface 2f of the body 2g and the inner peripheral surface of the spout 2d shown in FIG. In the present embodiment, the tube container 2 rotated by the rotating mechanism 6 described later is photographed. Therefore, the image of the tube container 2 taken is an developed image as shown in FIG.

Since the tube container 2 is a flexible resin tube container or a laminated tube container as described above, an opening that becomes an end portion of the body portion 2g due to the influence of gravity and the lateral support of the tube container holding portion 15 described later. There are cases where 2e is slightly deformed and does not become a perfect circle. When the tube container 2 is rotated and photographed in a deformed state in this way, the developed image of the tube container 2 is an image in which the opening 2e side of the body portion 2g is wavy, as shown in FIG. Become. The faster the rotation (rotation) of the tube container 2, the larger the amount of deformation of the wavy shape of the opening 2e tends to be. Therefore, it is preferable to adjust the tube container 2 so that the amount of deformation is reduced by controlling the rotation speed.

The illumination unit 19 spotlights the inside of the tube container 2 using a halogen lamp or a high-brightness LED lamp as a light source. Further, when the space on the side of the first camera 22 is narrow and the space for arranging the light source cannot be secured, the lighting unit 19 accommodates the light source in an empty space in the tube container inspection device 1, such as glass fiber. It is also possible to illuminate the inside of the tube container 2 by arranging the irradiation port of the illumination light on the side of the first camera 22 by routing the light source member of the above.

As shown in FIGS. 1 and 3, the rotation mechanism 6 includes a container rotating portion 34 and a second motor 24.
In the container rotating portion 34, a driving pulley 35 and a driven pulley 36 are arranged at predetermined intervals, and a rotating belt 37, which is a ring-shaped belt member, is hung on both pulleys 35 and 36 to form an endless track. The drive pulley 35 is rotated counterclockwise by the drive of the second motor 24 controlled by the motor drive control unit 7, and the rotary belt 37 is rotationally moved at a constant speed. For example, the rotation speed of the second motor 24 is controlled based on the constant speed rotation preset by the feedback control of the motor drive control unit 7 and the meandering correction information described later.

The rotating belt 37 is an annular belt member having a circular cross section and is made of a material having a high dynamic friction force and being hard to slip, for example, a resin material such as natural rubber or polyurethane. The rotating belt 37 is in contact with the roller 15a of the tube container holding portion 15 so as to be pressed against the roller 15a, and the rotating belt 37 rotating clockwise slides and rotates the roller 15a. Of course, the cross-sectional shape of the belt is not limited to a circle, but may be a rectangle or a trapezoid. Further, the surface of the belt may be provided with protrusions or dents to prevent the tube container 2 from slipping.

The rotary belt 37 has a length of contacting at least two pairs of rollers 15a at the same time, that is, rotating the two tube containers 2 at the same time. Further, when the tube container 2 reaches the photographing position P1, the rotation start position (the position where the rotating belt 37 contacts the roller 15a) is located upstream of the photographing position P1 so that the tube container 2 is in a constant rotation state in which imaging can be performed. ) Is set.
In this example, the container rotating portion 34 is arranged between the two conveyor chains 33 in the transport mechanism 3, and the rotating belt 37 comes into contact with the rotating belt 37 from below the roller 15a. As another example of arrangement, the container rotating portion 34 is arranged adjacent to the outside of the transport mechanism 3, the shaft of the roller 15a is extended laterally, and the rotating belt 37 comes into contact with the extending rotating shaft. A pair of rollers 15a may be rotated.

The transport mechanism 3 provided with the rotation mechanism 6 transports the tube container 2 laterally placed on the tube container holding portion 15 by the intermittent rotation of the conveyor chain 33 by intermittent movement that repeats movement-stop. At this time, the rotating belt 37 is rotating constantly.
The roller 15a of the tube container holding portion 15 starts rotating when it comes into contact with the rotating belt 37 at the rotation starting position. The motor drive control unit 7 drives the first motor 23, conveys the tube container 2 to the photographing position P1 defined by the first camera 22, and stops the tube container 2. After the tube container 2 is stopped at the photographing position P1, the inner surface of the tube container 2 is photographed by the first camera 22 over a specified distance (angle) of one round or more in a state where the rotation is continued.

The image processing unit 5 includes a meandering correction unit 27 and a defect enhancement processing unit 28. The image processing unit 5 performs meandering correction processing by the meandering correction unit 27 and defect enhancement processing by the defect enhancement processing unit 28, as well as brightness adjustment processing, on the image of the tube container 2 taken by the first camera 22.

Here, the meandering correction process by the meandering correction unit 27 will be described.
The first camera 22 of the line scan camera captures the rotation of the tube container 2 for about one and a half rounds so that the image of the inner peripheral surface of the tube container 2 over at least one circumference has overlapping portions on both sides. Since the rotating tube container 2 is made of a soft material, the opening 2e of the tube container 2 may be deformed due to gravity or centrifugal force of rotation to cause vertical and horizontal fluttering.

Therefore, as shown in FIG. 4, since the opening 2e of the tube container 2 is closer to the photographing optical system of the first camera 22, fluttering has an influence more than the spout portion 2d, and image distortion is more likely to occur. Due to the occurrence of this distortion, as shown in FIG. 5, the photographed image of the tube container 2 becomes an image in which the end portion of the opening 2e meanders irregularly.

In the image of the tube container 2 shown in FIG. 5, the meandering correction unit 27 has an arbitrary pixel at the end of the image from the position indicated by the broken line A1 on the body portion 2g of the tube container 2 to the meandering portion of the opening 2e. Is used as a reference pixel, a reference position is set, and the pixel sequence in the scanning direction is adjusted so as to line up with the reference position, so that the image of the end portion of the meandering opening 2e can be linearly aligned. The size of the pixel column in the scanning direction is adjusted so that, for example, the end of the longest row in the end image of the opening 2e is used as a reference position, and the number of pixels in the short row is supplemented according to the number of pixels in that row. Correct to. As a method of supplementing the pixels, for example, a pixel interpolation process may be performed in which any pixel on both sides is copied between adjacent pixels and pixels having the same brightness are inserted in between.

By such pixel interpolation processing, as shown in FIG. 6, the double line A2 in the body portion 2g is corrected so that the end portion of the opening 2e has the same number of pixels, and the end portion of the opening 2e meanders. Is corrected so that it becomes a straight line. If a new pixel that takes the average value of the brightness between adjacent pixels (intermediate brightness value) is generated and embedded between the pixels, the image will look smooth, but the adjacent pixels will be defective. If it hangs on a spot, it becomes difficult to judge whether it is good or bad, so the meandering correction process that incorporates the image of the average value is not suitable.
Further, the meandering correction unit 27 provides the control unit 9 and the motor drive control unit 7 with meandering correction information including a correction value indicating how much the meandering image is corrected when the meandering correction processing of the tube container 2 is performed. Output.

The defect enhancement processing unit 28 displays the image area determined as a defect portion by performing enhancement processing such as coloring so that it can be distinguished from other image areas by the determination unit 26 described later. Emphasize the image area of the defective part so that it stands out. Further, in the image enhancement process, as another method, the edge portion (frame line) of the image area of the defective portion may be blinked.

The control unit 9 controls the inspection unit 4, the motor drive control unit 7, the transport mechanism 3, the rotation mechanism 6, the image processing unit 5, the defective product exclusion unit 8, the storage unit 10, and the display unit 11.
The control unit 9 includes an arithmetic processing unit 25 and a determination unit 26. As the arithmetic processing unit 25 and the determination unit 26, for example, an electronic circuit such as a CPU or ASCI, or a processor including hardware is used. Each process in the arithmetic processing unit 25 and the determination unit 26 is executed according to the program stored in the storage unit 10. Further, the image processing unit 5, the motor drive control unit 7, the control unit 9, and the storage unit 10 can be replaced by a personal computer.

The arithmetic processing unit 25 is composed of an electronic circuit such as a CPU or ASCI, or a processor including hardware, and is used to inspect the tube container 2 for each component of the apparatus according to a preset program. Take control.
The arithmetic processing unit 25 sets a threshold value as a determination standard as one of the processes. For this threshold value, the upper and lower limits of an arbitrary range are set as the threshold value with the reference value as the center, and these threshold values are used as the judgment criteria of good or bad. Here, the pixel value is used as the luminance value.

First, the inside of a normal tube container 2 having no defects is photographed in advance, and the brightness value output from each pixel of the image sensor or the average brightness value of the pixel group in a predetermined region is used as a reference value.
Next, in the same tube container 2, a first sample in which foreign matter such as debris of an article containing a metal piece, hair, and body hair, which causes defects, is mixed, and dirt, shavings, etc., which also cause defects, Prepare a second sample that has been damaged such as a cut. These first and second samples are photographed by the first camera 22, and the brightness value of each pixel of the image sensor is calculated.

Normally, when a foreign substance is present, a shadow of illumination light, reflected light, or the like is generated, so that a pixel that outputs a luminance value having a height difference higher than the luminance value of the reference value is generated. Therefore, a difference in brightness is generated between the pixels of the image of the normal surface in the tube container 2 and the pixels of the image of the foreign matter, and an edge is generated on the image (on the display screen). For example, when the reflectance is lower than that of the inner surface of the tube container 2 or when the shadow of illumination is generated like hair, the brightness value is lower than the reference value. On the contrary, since the reflectance of a metal piece or the like is high, the brightness value is higher than the reference value. Therefore, it is necessary to set an absolute threshold value for the reference value or set a threshold value for both positive and negative values for the reference value.

The difference between the above-mentioned reference value and the respective brightness values of the images of the first and second samples is taken, and a threshold value as a judgment standard is set based on these differences. In addition, in order to identify the cause of the defect by setting the image area exceeding the threshold value as the defect location, a defect information file consisting of defect information of a foreign substance shape (for example, a linear shape in the case of hair) is created in advance. , Stored in the storage unit 10 described later. Since these reference values and threshold values may differ depending on the type or material of the tube container, the tube container to be inspected is measured and set before the start of the inspection. Further, a plurality of types of tube containers may be measured in advance, reference values may be obtained for each, an inspection condition file may be created, and this may be stored in the storage unit 10.

The determination unit 26 sets the threshold value and defect information read from the storage unit 10 as determination criteria. The determination unit 26 compares the pixel value detected from the image of the tube container 2 output from the image processing unit 5 with the threshold value, and has an edge for pixels above the threshold value. As a defect. Further, for all images, defects are detected by comparing the threshold value and the pixel value in the same manner.

Further, the control unit 9 uses the meandering correction information including the correction value for correcting the meandering image of the tube container 2 acquired from the meandering correction unit 27 so that the photographed rotating tube container 2 is less deformed. It is also possible to perform feedback control for adjusting the rotation speed of the container rotating unit 34 by the motor drive control unit 51. For example, in the meandering correction information, when the correction rate is higher than the preset reference, that is, when the meandering amplitude of the opening 2e of the tube container 2 is large, the control unit 9 reduces the meandering amplitude. The rotation speed of the container rotation unit 34 is adjusted by the motor drive control unit 51.

The storage unit 10 stores programs and information for the control unit 9 to drive and control each unit of the device. The storage unit 10 is composed of an HDD (Hard Disk Drive), an SSD (Solid State Drive), or the like in order to secure a sufficient storage capacity. Further, the storage unit 10 stores the data of the judgment criteria such as the above-mentioned threshold value and the judgment result for the judgment unit 26 to judge the quality as an inspection condition file. Further, the foreign matter shape that causes the defect (for example, in the case of hair, the linear shape) is stored as defect information.

The display unit 11 uses a display device such as a liquid crystal display or an organic EL display, for example. Further, a touch panel provided with a touch pad as an input unit on the display screen may be used. The display unit 11 selectively selects the driving status, inspection conditions, input information, photographed image of the tube container 2, the image of the tube container 2 in which the defective portion is emphasized, and the like transmitted from the control unit 9. Display in. Further, the display unit 11 can enlarge and display the defective portion of the displayed image of the tube container 2 under the control of the control unit 9. The display unit 11 is not limited to one unit, and may be separately arranged in a monitor room or the like provided at another place in addition to the display unit 11 mounted on the inspection device.

The foreign matter removing unit 12 is arranged in front of (upstream) the photographing unit 20 on the transport path of the transport mechanism 3. The foreign matter removing unit 12 is provided with a nozzle for ejecting compressed air, and the foreign matter removing unit 12 arranges a stopper 13 at a position facing the tube container 2 in between. The stopper 13 engages the shoulder portion 2b or the spout portion 2d of the tube container 2 so that the tube container 2 on the tube container holding portion 15 does not move when compressed air is ejected to the inside and the outside of the tube container 2. Stop. The stopper 13 may have not only a function of preventing the tube container 2 from moving but also a function of taking a reference of the mounting position of the tube container 2. In this case, it is attached to each roller 15a of the roller 15a holding portion 15 in advance so that the spout portion 2d enters between the stoppers and the shoulder portion 2b of the tube container 2 is hooked.

The foreign matter removing unit 12 blows compressed air from a nozzle into and outside the tube container 2 immediately before the inspection, and blows off the foreign matter that has entered the inside of the tube container 2 to remove the foreign matter. For example, if the hair adheres to the inside of the tube container 2, it can be removed before the inspection, so that the number of tube containers 2 judged to be defective is reduced.

The defective product removing unit 8 is arranged behind (downstream) the photographing unit 20 on the transport path of the transport mechanism 3. The defective product removing unit 8 blows compressed air from diagonally downward, for example, onto the tube container 2 determined by the determination unit 26 of the control unit 9 to have a defective portion, and pushes it out from above the tube container holding unit 15. It is stored in the defective product storage box 29. As the exclusion mechanism, in addition to compressed air, a mechanical part such as an arm or a lever is used to move the tube container 2 on the tube container holding portion 15 to the defective product storage box 29, or move the tube container 2 downward. It may be ejected from and moved to the defective product storage box 29.

The inspection of the tube container by the tube container inspection device of the first embodiment configured as described above will be described.
First, the tube container inspection device 1 is started, the setting screen is selected on the menu screen displayed on the display screen on the display unit 11, and the inspection conditions and the like are set. At this time, the storage unit 10 inputs the information necessary for the inspection such as the threshold value necessary for the pass / fail judgment to the judgment unit 26. Here, the above-mentioned automatic control mode is selected, the motor drive control unit 7 is feedback-controlled, and the rotation mechanism 6 is constantly adjusted.

Next, the flexible tube container 2 manufactured by the container manufacturing apparatus (not shown) in the manufacturing line 100 is placed so as to be delivered between the rollers 15a of the tube container holding portion 15 on the first conveyor 21. The first conveyor 21 steps the tube container 2 so as to convey it to the rotating mechanism 6 and the inspection unit 4.

The tube container 2 on the first conveyor 21 first stops at a nozzle (not shown) that ejects compressed air from the foreign matter removing portion 12. At this time, the stopper 13 is addressed to the spout 2d of the tube container 2, and the tube container 2 is locked inside the tube container 2 so as not to cause a misalignment from above the tube container holding portion 15. Compressed air is ejected from the nozzle. Foreign matter adhering to the inside or the outside of the tube container 2 is blown off and removed from the tube container 2.

Next, the tube container 2 is moved from the front 0 side of the foreign matter removing portion 12 by the first conveyor 21 to reach the container rotating portion 34. The roller 15a of the tube container holding portion 15 is in contact with and rubbed against the rotating belt 37 of the container rotating portion 34, and rotates according to the sliding of the rotating belt 37. In this example, the rotation direction of the rotary belt 37 is opposite to the rotation direction of the first conveyor 21, but the rotation direction of the rotary belt 37 is not particularly limited.

The tube container 2 is conveyed by the first conveyor 21 in a rotated state, and stops at a preset photographing position P1 of the first camera 22 of the photographing unit 20. Even after stopping, the tube container 2 maintains a state of constant speed rotation. In the present embodiment, by rotating the tube container 2 first before reaching the shooting position P1 of the first camera 22, stable constant speed rotation is reached when the shooting position is reached. Shooting can be started immediately.

At the photographing position P1 of the first camera 22, the inside of the tube container 2 in which the tube container 2 makes at least one rotation or more is photographed. The photographing time by the first camera 22 is set by the rotation speed of the tube container 2. For this reason, the faster the rotation speed of the tube container 2, the shorter the shooting time, but the faster the rotation speed, the more likely it is that bad behavior such as shaking or vibration of the tube container 2 will occur, so that the limit is such that shaking or vibration does not occur. The rotation speed of is preferable.

The image of the tube container 2 taken by the first camera 22 is transmitted to the image processing unit 5. The image processing unit 5 uses the meandering correction unit 27 to adjust the image size of the image from the body 2g of the tube container 2 to the end of the opening 2e by pixel interpolation processing as described with reference to FIGS. 5 and 6. Is performed to correct the image so that the opening end is a straight line. The corrected image is transmitted to the determination unit 26 of the control unit 9.

Next, the control unit 9 sets the threshold value and the defect information read from the storage unit 10 in the determination unit 26 as a determination criterion. The determination unit 26 compares the pixel value (luminance value) detected from the image of the tube container 2 output from the image processing unit 5 with the reference value (normal brightness value), and sets a threshold value as a determination reference. Pixels with the above differences are extracted as defects, assuming that edges have occurred. Further, for all images, defects are detected by comparing the threshold value and the detected pixel value in the same manner.

The determination unit 26 transmits an image of the tube container 2 from which the defect portion is extracted to the defect enhancement processing unit 28. The defect enhancement processing unit 28 performs coloring treatment of the edge portion and the like so as to emphasize the defect portion included in the image of the tube container 2, and then transmits the image to the display unit 11.
The display unit 11 displays an image of the tube container 2 input from the defect enhancement processing unit 28 of the image processing unit 5 together with inspection information including the cause of the defect and the like. The inspection information includes, for example, the cause of the defective portion (foreign matter name), shooting conditions, shooting time, and product number (inspection number, lot number).

After the imaging is completed, the tube container 2 is conveyed to the first conveyor 21, moves out of the rotating belt 37, and stops in front of the defective product removing unit 8. After this stop, the control unit 9 instructs the defective product exclusion unit 8 to remove the tube container 2 determined by the determination unit 26 to have a defective portion. The defective product removing unit 8 blows compressed air onto the tube container 2 determined to have a defective portion according to the instruction from the control unit 9, or uses a mechanical part such as an arm or a lever to hold the tube container. The tube container 2 on 15 is moved to the defective product storage box 29 and stored.

The tube container 2 housed in the defective product storage box 29 is visually confirmed by an inspector. The tube container 2 that can be easily cleaned due to the generated defects such as foreign matter such as hair being mixed in is returned to the production line of the tube container 2 that has been judged to be non-defective after the cleaning process, and scratches and stains that cannot be removed unless thoroughly cleaned The resulting tube container 2 is discarded.
Further, the tube container 2 which is judged to be non-defective and non-defective by the tube container inspection device 1 is immediately packed and shipped, or after the contents are filled in the tube container 2, the opening 2e is sealed. It is processed.

As described above, the tube container inspection device of the present embodiment is composed of a transport mechanism and an inspection unit having a space-saving and simple straight transport path, and therefore is the end or contents of the existing production line. It can be retrofitted just before the material filling device, and can detect foreign matter contamination, scratches and dirt just before shipping and packing or just before filling the contents.

The tube container inspection device of the present embodiment can inspect the entire number of tube containers manufactured. By arranging the foreign matter removing part immediately before the inspection part on the transport mechanism, the foreign matter mixed in the tube container is removed, so that the number of tube containers in which defective products having defective parts are determined can be reduced. .. Further, by arranging the defective product exclusion unit after the inspection unit on the transport mechanism, it is possible to selectively eliminate the tube container 2 determined to have a defective portion before shipping and packing or filling the contents. ..

Further, since the tube container inspection device of the present embodiment inspects while the tube container is tilted laterally and transported, it is more difficult for foreign matter to enter through the opening than the transport mechanism in which the opening of the tube container faces upward.
Since the tube container inspection device uses a line scan camera with a deep depth of field using the Scheimpflug principle, it is possible to take an image in which the entire inside of the tube container is in focus with one camera.

[Second Embodiment]
In this embodiment, the configuration of the inspection unit 4 is different from that in the first embodiment. In the first embodiment described above, one line scan camera was used to photograph and inspect the inner peripheral surface of the tube container, but in the second embodiment, at least two line scans are performed. A camera is used to photograph the inner peripheral surface and the outer peripheral surface of the tube container, respectively, for inspection. In the configuration of the present embodiment, the same reference numerals will be given to the components equivalent to those of the first embodiment described above, and the description thereof will be omitted.

FIG. 7 is a diagram showing a conceptual overall configuration example of the tube container inspection device including the transfer line according to the present embodiment. FIG. 8 is a block diagram showing a configuration example of the tube container inspection device according to the present embodiment, and FIG. 9 is a diagram showing an arrangement example of a camera for photographing the outer peripheral surface of the tube container.

The inspection unit 4 includes a photographing unit 20 and a lighting unit 19. The photographing unit 20 includes a first camera 22 that photographs the inside of the tube container 2, and a second camera 41 that photographs the outer peripheral surface of the tube container 2. In this embodiment, the configuration example uses two cameras, but the present invention is not limited to this, and it can be implemented with a minimum of two cameras, but the number of cameras can be increased as needed. Is.

As shown in FIG. 7, the first camera 22 and the second camera 41 sandwich the first conveyor 21 in between, and take pictures in accordance with the shooting range (angle of view) of taking pictures of the inner peripheral surface and the outer peripheral surface of the tube container 2. It is arranged at positions P1 and P2. Specifically, as shown in FIG. 9, the inside of the tube container 2 is photographed by the first camera 22 with respect to the tube container 2 placed on the tube container holding portion 15 which is continuously conveyed. 2 The camera 41 can simultaneously or continuously take pictures of the outer surface side of the tube container. In particular, since no constituent parts are arranged above the first conveyor 21 of the transport mechanism 3, there is a space that can be effectively used. It is also possible to arrange the second camera 41 using this space.

As shown in FIG. 9, the second camera 41 of the present embodiment has a configuration in which a deep depth of field can be obtained by using the principle of Scheimpflug in the arrangement of the photographing lens (objective lens) 41a and the image pickup element 41b described above. is there. The second camera 41 focuses on the entire surface of the surface intersecting the intersection G2 (focus position P2). Therefore, the second camera 41 is arranged so as to intersect the intersection G2 with the extending surface of the outer peripheral surface 2a of the tube container 2 to be photographed. With this arrangement, it is possible to obtain an image in focus from the spout portion 2d of the spout 2c of the tube container 2 to the inside of the shoulder portion 2b and the outer peripheral surface 2a of the body portion 2g shown in FIG.

The image of the outer peripheral surface of the tube container 2 taken by the second camera 41 may be taken by rotating the tube container 2 in a deformed state, as in the developed image shown in FIG. 5 described above. In this case, the image has a wavy shape on the opening 2e side of the body 2g. In the image of the tube container 2 taken by the second camera 41, the image processing unit 5 also performs the meandering correction processing by the meandering correction unit 27 and the enhancement processing of the image region of the defect portion by the defect enhancement processing unit 28.

The inspection of the tube container by the tube container inspection device of the second embodiment configured as described above will be described. In the inspection procedure of the present embodiment, the inspection procedure equivalent to that of the first embodiment described above will be briefly described.
First, the tube container inspection device 1 is started, and the threshold value, inspection conditions, and the like are set.
Next, the soft tube container 2 manufactured by the container manufacturing apparatus is placed on the tube container holding portion 15 of the first conveyor 21, conveyed by step movement, and stopped in front of the foreign matter removing portion 12. Compressed air is ejected toward the tube container 2. At this time, two nozzles may be provided so that the compressed air hits the inside and the outside of the tube container 2. When foreign matter has entered the inside of the tube container 2, the foreign matter is blown off by the compressed air ejected by the foreign matter removing unit 12 and is discharged to the outside of the tube container 2. After that, the tube container 2 reaches the container rotating portion 34 and is rotated according to the rotation of the container rotating portion 34.

The tube container 2 is conveyed to a common imaging position of the first camera 22 and the second camera 41 of the photographing unit 20 and stopped while being rotated. In this common shooting position, the tube container 2 that shoots the inside of the tube container 2 stops at the shooting position P1 of the first camera 22, and the inside of the tube container 2 is stopped at the shooting position P2 of the second camera 41. The tube container 2 for which the shooting of the above has been completed stops. Further, even after stopping, each tube container 2 maintains a rotated state.
Next, the inside of the tube container 2 rotating by the first camera 22 is photographed for at least one rotation, and then the tube container 2 rotating by the second camera 41 is photographed for at least one rotation. The outer peripheral surface of the tube container 2 is photographed. Simultaneous shooting with the first camera 22 and the second camera 41 is also possible, but since the two lighting units 19 are arranged to face each other, the illumination light of the other side enters the shooting optical system and flares. If there is a risk of it occurring, set a time difference and shoot continuously.

The internal image and the outer peripheral surface image of the tube container 2 taken by the first camera 22 and the second camera 41 are transmitted to the image processing unit 5. In the image processing unit 5, the internal image and the outer peripheral surface image are subjected to image processing by the meandering correction unit 27, and the end portion of the image is corrected to a straight line. The corrected image is transmitted to the control unit 9.

Next, the determination unit 26 of the control unit 9 performs edge detection on the internal image and the outer peripheral surface image of the tube container 2 using a preset threshold value, and determines the contour (edge) of the defective portion. Extract the shape. The determination unit 26 transmits an image of the tube container 2 from which the defect portion is extracted to the defect enhancement processing unit 28. The defect enhancement processing unit 28 performs coloring treatment or the like on the internal image and the outer peripheral surface image of the tube container 2 so as to emphasize the defective portion included in each image, and then transmits the image to the display unit 11. The display unit 11 displays an image of the highlighted tube container 2 together with inspection information including the cause of defects and the like. After such a determination, the defective product exclusion unit 8 removes the tube container 2 having the defective portion, moves the tube container 2 to the defective product storage box 29, and stores the tube container 2.

As described above, according to the tube container inspection device of the present embodiment, it is possible to obtain the same effect as that of the first embodiment described above. Further, since the cameras are arranged on both sides of the first conveyor for transporting, the internal image and the outer peripheral surface image of the tube container 2 can be acquired and inspected for the presence or absence of defects without lengthening the transport line. Can be done.
The surface of the roller 15a of the tube container holding portion 15 is preferably subjected to anti-slip processing so that the rotational force is efficiently transmitted to the tube container 2. In addition to the surface processing of the roller 15a, for example, a conductive resin cap and a rubber cap may be coated.
Further, in the second embodiment, a line scan camera is used as the camera, but when photographing the outer peripheral surface of the tube container, an area camera equipped with an area sensor as an image sensor may be used in combination.

The embodiments of the present invention described above are not limited. At the implementation stage, it is possible to make various modifications without departing from the gist. Further, the above-described embodiments include inventions at various stages, and various inventions are extracted by appropriate combinations of the plurality of disclosed constituent requirements. Further, even if some constituent requirements are deleted from all the constituent requirements shown in the embodiment, the problem described in the column of the problem to be solved by the invention can be solved, and the effect described in the column of the effect of the invention can be solved. If is obtained, the configuration in which this configuration requirement is deleted is extracted as an invention.

1 ... Tube container inspection device, 2 ... Tube container, 3 ... Conveyor mechanism, 4 ... Inspection unit, 5 ... Image processing unit, 6 ... Rotation mechanism, 7 ... Motor drive control unit, 8 ... Defective product elimination unit, 9 ... Control Unit, 10 ... Storage unit, 11 ... Display unit, 12 ... Foreign matter removal unit, 13 ... Stopper, 15 ... Tube container holding unit, 19 ... Lighting unit, 20 ... Imaging unit, 21 ... 1st conveyor, 22 ... 1st camera , 23 ... 1st motor, 24 ... 2nd motor, 25 ... Arithmetic processing unit, 26 ... Judgment unit, 27 ... Serpentine correction unit, 28 ... Defect enhancement processing unit, 29 ... Defective product storage box, 34 ... Container rotation unit, 41 ... 2nd camera, 100 ... Production line.

Claims (5)

A holding portion having a shoulder portion at one end and a roller pair that rotatably holds a soft tube container having an opening at the other end in a sideways state.
A transport mechanism having a plurality of the holding portions and having an endless track forming a linear transport path,
The tube container is provided with a belt member to be arranged in the transport mechanism or adjacent to the transport mechanism, and the roller pair is rotated by sliding by the rotating belt member to mount the tube container on the holding portion. Rotation mechanism to rotate and
The imaging lens and the imaging element are arranged so that the surface extending the main surface of the photographing lens and the surface extending the imaging surface of the imaging element intersect at one intersection, and the tube container that rotates in the sideways state. An imaging unit having a first camera that photographs the inside of the container from the opening at the other end on the focusing surface that intersects the intersection.
Control to detect an edge in which the difference between adjacent pixels is equal to or more than a predetermined threshold value with respect to the image of the inside of the tube container taken by the first camera, and extract the edge as a defect portion. Department and
A meandering correction unit that linearly aligns the meandering part with respect to the meandering part generated in the image of the opening at the other end of the rotating tube container taken by the first camera, and the defective part. An image processing unit including a defect enhancement processing unit that enhances an image including coloring in order to distinguish it from other image areas, and an image processing unit.
A tube container inspection device equipped with. The rotating mechanism includes a rotating belt spanned over a plurality of pulleys and a motor for rotating the pulleys.
The rotating belt sequentially rotates the roller pair that is moved by the transport mechanism, and before arriving at the photographing position of the first camera, the tube container placed on the roller pair is set to a constant value. The tube container inspection device according to claim 1, wherein the rotation is reached. The tube container inspection device further
A foreign matter removing unit, which is arranged in front of the imaging unit on the transport path of the transport mechanism and ejects compressed air to the tube container,
A defective product exclusion unit, which is arranged after the pre-imaging unit on the transfer path of the transfer mechanism and excludes the tube container determined by the control unit to have the defective portion from the transfer mechanism.
The tube container inspection apparatus according to claim 1. The imaging unit further
The second photographing lens and the second imaging element are arranged so that the surface extending the main surface of the second photographing lens and the surface extending the imaging surface of the second imaging element intersect at one intersection, and the sideways state. The tube container inspection device according to claim 1, further comprising a second camera that photographs the outer peripheral surface of the tube container including the shoulder portion on the focal plane intersecting the intersection of the tube container that rotates in. The tube container inspection device is a tube container inspection device that can be retrofitted immediately before an existing production line that manufactures a tube container or a filling device that fills the tube container with contents. The tube container inspection device described in.