JP7466613B1 - Inspection equipment and blister packing machines - Google Patents

Abstract

[Problem] To provide an inspection device etc. capable of more reliably distinguishing and detecting the presence or absence of a hole and the quality of the thickness of a container film by a single imaging means. [Solution] The inspection device 21 includes a single camera 52 capable of capturing an image of light transmitted through the container film to obtain luminance image data, and an image processing device 53 that judges the quality of the container film 3 based on the luminance image data. An illumination device 51 simultaneously irradiates the container film with light of wavelength λ0, the transmittance of which varies toward the camera 52 depending on the thickness of the container film, and light of wavelength λ1, which is lower than the wavelength λ0 and does not transmit through the container film. The image processing device 53 judges an area with a luminance higher than luminance L1 in the luminance image data to be a hole, and judges the quality of the thickness of the container film based on the luminance of the area in the luminance image data that is equal to or lower than luminance L1. [Selected Figure] Figure 5

Description

The present invention relates to an inspection device for inspecting plastic container films, and a blister packaging machine equipped with the inspection device.

A type of blister sheet commonly used in the pharmaceutical industry is known as a PTP (press-through pack) sheet. A PTP sheet is made of a resin container film with a pocket in which contents such as tablets are stored, and a cover film that is attached to the container film so as to seal the opening side of the pocket.

The above-mentioned blister sheet can be manufactured by a blister packaging machine. The blister packaging machine is equipped with a means for forming pockets in a belt-shaped container film being conveyed, a means for filling the pockets with contents, a means for attaching a belt-shaped cover film to the container film so as to seal the opening side of the pocket, and a means for punching out the belt-shaped blister film consisting of the container film and cover film into sheets.

However, during the process of manufacturing blister sheets, the balance of thicknesses of various parts of the container film can sometimes be unintentionally lost.

In light of this, an inspection device has been proposed for determining whether the thickness of the container film is good or bad, which includes an irradiation means for irradiating a pocket portion with a predetermined light and an imaging means for obtaining transmission image data based on the light transmitted through the pocket portion, and which determines whether the thickness of the container film is good or bad based on the transmission image data (see, for example, Patent Document 1). In this inspection device, the transmission image data is luminance image data in which the luminance of each portion differs depending on the light transmittance of the container film. By using the luminance of each portion in this luminance image data, the thickness of each portion of the container film is calculated, and a pass/fail determination is made based on the calculated thickness.

In addition, holes (relatively small holes called pinholes, relatively large holes, tears, etc.) may occur in the container film, and if the holes are in the pocket area, the sealing ability of the contents will be compromised.

In response to this, an inspection device has been proposed that uses the contents filled in the pocket to detect the presence or absence of holes in the pocket (see, for example, Patent Document 2, etc.). This inspection device is equipped with an irradiation means that irradiates the container film with a predetermined light, and an imaging means that is provided on the opposite side of the container film from the irradiation means, and the imaging means is capable of imaging the light that has passed through the container film and reflected off the contents. Then, by determining the brightness of the surface of the contents based on the image data obtained by the imaging means, it is possible to detect the presence or absence of holes.

JP 2019-31302 A JP 2009-36522 A

However, holes (pinholes, etc.) are a serious defect in that they impair the sealing of the contents. Therefore, in order to sort out whether the product is good or bad and take measures to prevent defects, it is necessary to detect the presence or absence of holes separately from the quality of the thickness of the container film.

In this regard, if we think simply about it, by using brightness image data as in the inspection device of Patent Document 1, it may be possible to distinguish between the presence or absence of holes and the quality of the thickness of the container film.

However, for example, in areas where the container film is sufficiently thin, such as the bottom of a pocket, the light transmittance can approach 100%. Therefore, it is difficult to distinguish between holes where the light transmittance is 100% and areas where the container film is sufficiently thin in the brightness image data. Therefore, simply using the brightness image data may not be able to distinguish and detect the presence or absence of holes and the quality of the thickness of the container film.

It is therefore conceivable to provide both an inspection device for determining whether the thickness of the container film is good or bad (such as the inspection device disclosed in Patent Document 1) and an inspection device for detecting the presence or absence of holes (such as the inspection device disclosed in Patent Document 2). However, in this case, it is necessary to provide at least multiple imaging means, which may lead to an increase in the size of the device and an increase in costs related to manufacturing and maintenance, etc.

The present invention has been made in consideration of the above circumstances, and its purpose is to provide an inspection device etc. that can more reliably distinguish and detect the presence or absence of holes and the quality of the container film thickness using a single imaging means, and that can reduce the size of the device and the costs associated with manufacturing etc.

Below, each means suitable for achieving the above objective will be explained item by item. In addition, the specific effects of the corresponding means will be noted as necessary.

Means 1. An inspection device for inspecting a resin container film having a pocket portion for accommodating contents,
An irradiation means for irradiating the container film with a predetermined light;
an imaging means that is provided on the opposite side of the container film from the illumination means and is capable of imaging light that is irradiated by the illumination means and transmitted through the container film to obtain brightness image data;
A determination means for determining whether the container film is good or bad based on the brightness image data obtained by the imaging means,
The irradiation means is configured to irradiate the container film with only light of a wavelength λ0, the transmittance of which varies depending on the thickness of the container film toward the imaging means , and light of a wavelength λ1, the wavelength of which is shorter than the wavelength λ0 and does not pass through the container film, at one time;
The imaging means is configured to be capable of imaging at least light of wavelength λ0 and light of wavelength λ1,
The determination means is
a hole determination means for determining, in the brightness image data obtained by the imaging means, an area having a brightness higher than a predetermined brightness L1 as a hole;
An inspection device characterized by having a thickness determination means for determining whether the thickness of the container film is good or bad based on the brightness of an area in the brightness image data that is below brightness L1.

According to the above-mentioned means 1, the irradiation means irradiates the container film with only light of wavelength λ0, the transmittance of which varies depending on the thickness of the container film toward the imaging means , and light of wavelength λ1, which is shorter than wavelength λ0 and does not pass through the container film, at one time.The imaging means obtains luminance image data by capturing images of these lights.

Here, for areas in the container film with holes (such as pinholes), both light of wavelength λ0 and light of wavelength λ1 are transmitted, resulting in a relatively large luminance in the luminance image data. On the other hand, for thin areas in the container film (such as the bottom of a pocket), light of wavelength λ1 is not transmitted, and only light of wavelength λ0 is transmitted in an amount corresponding to the thickness of the area, resulting in a relatively small luminance in the luminance image data. Therefore, in the luminance image data, the difference between the luminance of the hole and the luminance of the thin area in the container film can be made relatively large.

As a result, the hole determination means can determine the presence or absence of holes in a manner that is sufficiently distinct from thin-walled portions of the container film. In addition, the thickness determination means can determine the quality of the thickness of the container film in a manner that is sufficiently distinct from holes. This makes it possible to more reliably distinguish and detect the presence or absence of holes from the quality of the thickness of the container film.

In addition, since only one imaging means is required, it is possible to miniaturize the device and reduce costs related to manufacturing, etc.

Means 2. An inspection device for inspecting a resin container film having a pocket portion for accommodating contents, comprising:
An irradiation means for irradiating the container film with a predetermined light;
an imaging means that is provided on the opposite side of the container film from the illumination means and is capable of imaging light that is irradiated by the illumination means and transmitted through the container film to obtain brightness image data;
A determination means for determining whether the container film is good or bad based on the brightness image data obtained by the imaging means,
The irradiation means is configured to irradiate the container film with only light of wavelength λ0, the transmittance of which varies depending on the thickness of the container film toward the imaging means, light of wavelength λ1, which is shorter than wavelength λ0 and does not pass through the container film, and light of wavelength λ2, which is longer than wavelength λ0 and completely passes through the container film, at one time;
the imaging means is configured to be capable of imaging at least light of wavelength λ0, light of wavelength λ1, and light of wavelength λ2;
The determination means is
a hole determination means for determining, in the brightness image data obtained by the imaging means, an area having a brightness higher than a predetermined brightness L1 as a hole;
a thickness determination means for determining whether or not the thickness of the container film is good based on the brightness of an area equal to or less than the brightness L1 in the brightness image data; and
the determining means includes a foreign matter determining means for determining, in the luminance image data, an area having a luminance lower than a predetermined luminance L4 as a foreign matter,
The inspection device is characterized in that the thickness determination means is configured to determine whether the thickness of the container film is good or bad based on the brightness of the area in the brightness image data that is between brightness L4 and brightness L1.

Sometimes, foreign matter may adhere to the container film. If the contents are medicines or food, the presence or absence of foreign matter can be a serious hygiene defect. For this reason, it is necessary to detect the presence or absence of foreign matter separately from the quality of the container film thickness, both for sorting quality and for taking measures against defects.

In this regard, according to the above-mentioned means 2, the irradiation means irradiates the container film with only light of wavelength λ0, the transmittance of which varies depending on the thickness of the container film toward the imaging means, light of wavelength λ1, which is shorter than the wavelength λ0 and does not pass through the container film, and light of wavelength λ2, which is longer than the wavelength λ0 and completely passes through the container film, at one time.The imaging means then obtains luminance image data by capturing these lights.

Here, in the area of the container film where a foreign object (light-shielding foreign object) is attached, the light of wavelengths λ0, λ1, and λ2 is not transmitted at all or almost not at all, so the luminance in the luminance image data is very small. On the other hand, in the area of the thick part of the container film (such as the flange portion of means 3 described below), at least the light of wavelength λ2 is transmitted, so the luminance in the luminance image data is relatively large. Therefore, in the luminance image data, the difference between the luminance of the foreign object and the luminance of the thick part of the container film can be made relatively large.

As a result, the foreign matter determination means can determine the presence or absence of foreign matter in a manner that is sufficiently distinct from thick portions of the container film. In addition, the thickness determination means can determine the pass/fail of the thickness of the container film in a manner that is sufficiently distinct from foreign matter. This makes it possible to more reliably distinguish and detect the presence or absence of foreign matter from the pass/fail of the thickness of the container film.

Means 3. An inspection device for inspecting a resin container film having a pocket portion for accommodating contents, comprising:
An irradiation means for irradiating the container film with a predetermined light;
an imaging means that is provided on the opposite side of the container film from the illumination means and is capable of imaging light that is irradiated by the illumination means and transmitted through the container film to obtain brightness image data;
A determination means for determining whether the container film is good or bad based on the brightness image data obtained by the imaging means,
The irradiation means is configured to simultaneously irradiate the container film with light of a wavelength λ0, the transmittance of which varies toward the imaging means depending on the thickness of the container film, and light of a wavelength λ1, which is shorter than the wavelength λ0 and does not pass through the container film;
The imaging means is configured to be capable of imaging at least light of wavelength λ0 and light of wavelength λ1,
The determination means is
a hole determination means for determining, in the brightness image data obtained by the imaging means, an area having a brightness higher than a predetermined brightness L1 as a hole;
a thickness determination means for determining whether or not the thickness of the container film is good based on the brightness of an area equal to or less than the brightness L1 in the brightness image data;
the container film has a flange portion that is located at an opening periphery of the pocket portion, is thicker than the pocket portion, and is flat;
the irradiation means is configured to irradiate, as the light of wavelength λ0, light of wavelength λ01, the transmittance of which through the pocket portion to the imaging means varies depending on a thickness of the pocket portion, and light of wavelength λ02, which has a wavelength longer than the wavelength λ01 and the transmittance of which through the flange portion to the imaging means varies depending on a thickness of the flange portion;
The thickness determination means is
a pocket thickness determining means for determining whether a thickness of the pocket is good or bad based on the brightness of an area corresponding to the pocket in the brightness image data;
An inspection device characterized by comprising a flange thickness determination means for determining whether the thickness of the flange portion is good or bad based on the brightness of an area corresponding to the flange portion in the brightness image data.

According to the above-mentioned means 3, the irradiation means irradiates, as the light of wavelength λ0, light of wavelength λ01 whose light transmittance in the pocket varies depending on the thickness of the pocket, and light of wavelength λ02 whose wavelength is longer than wavelength λ01 and whose light transmittance in the flange varies depending on the thickness of the flange. Then, the imaging means obtains luminance image data by imaging these lights.

Here, for the pocket portion, light of wavelength λ01 is transmitted in an amount corresponding to the thickness of the pocket portion, and light of wavelength λ02, which is a longer wavelength than wavelength λ01, is transmitted, so the luminance in the luminance image data is relatively large. On the other hand, for the flange portion, light of wavelength λ02 is transmitted in an amount corresponding to the thickness of the flange portion, but light of wavelength λ01, which is a shorter wavelength than wavelength λ02, is not easily transmitted, so the luminance in the luminance image data is relatively small. Therefore, in the luminance image data, the difference between the luminance of the pocket portion and the luminance of the flange portion can be made relatively large.

As a result, the pocket thickness determination means can determine whether the thickness of the pocket portion is good or bad in a manner that is sufficiently distinct from the flange portion. Also, the flange thickness determination means can determine whether the thickness of the flange portion is good or bad in a manner that is sufficiently distinct from the pocket portion. This can increase the accuracy of determining whether the thickness of the pocket portion and the flange portion are good or bad.

Means 4. A method comprising the inspection device according to any one of means 1 to 3 ,
A blister packaging machine that produces a blister sheet in which a cover film is attached to the container film so as to cover the pocket portion while contents are placed in the pocket portion formed in the container film.

The above-mentioned method 4 provides the same effect as the above-mentioned method 1.

FIG. 2 is a perspective view showing a PTP sheet. FIG. 2 is a partially enlarged cross-sectional view of a PTP sheet. FIG. 2 is a perspective view showing a PTP film. FIG. 1 is a schematic diagram showing a general configuration of a PTP packaging machine. FIG. 2 is a block diagram showing a schematic configuration of an inspection device. FIG. 2 is a schematic diagram showing a schematic configuration of a lighting device and the like. This is a graph showing the relationship between the wavelength of the irradiated light and the transmittance of the container film when the thickness of the container film is T1, T2, T3, or T4, and the wavelengths λ0, λ1, or λ2 of the light irradiated from the light source. 13 is a table illustrating the amount of received light relating to a pocket portion, a flange portion, a foreign object, and a hole. FIG. FIG. 4 is a schematic diagram showing an example of luminance image data. FIG. 13 is a schematic diagram showing a schematic configuration of a lighting device and the like in another embodiment. In another embodiment, this is a graph showing the relationship between the wavelength of the irradiated light and the transmittance of the container film when the thickness of the container film is T1, T2, T3, or T4, and the wavelengths λ0 and λ1 of the light irradiated from the light source. FIG. 11 is a table illustrating the amount of received light relating to a flange portion, a pocket portion, and a hole portion in another embodiment. FIG. 13 is a schematic diagram showing a schematic configuration of a lighting device and the like in another embodiment. In another embodiment, this is a graph showing the relationship between the wavelength of the irradiated light and the transmittance of the container film when the thickness of the container film is T1, T2, T3, or T4, and the wavelengths of light irradiated from the light source are λ01, λ02, λ1, or λ2. FIG. 11 is a table illustrating the amount of received light relating to a flange portion, a pocket portion, a foreign object, and a hole in another embodiment.

One embodiment will be described below with reference to the drawings. First, the configuration of the PTP sheet as a "blister sheet" will be described.

As shown in Figures 1 and 2, the PTP sheet 1 has a container film 3 with multiple pockets 2 and a cover film 4 attached to the container film 3 so as to cover the pockets 2.

The container film 3 is made of a transparent thermoplastic resin material such as PP (polypropylene) or PVC (polyvinyl chloride) and has light-transmitting properties. The thickness of the container film 3 is relatively small (e.g., 120 μm or more and 300 μm or less).

The container film 3 extends outward from the opening end of the pocket portion 2 and has a flat flange portion 3a to which the cover film 4 is attached. The flange portion 3a is thicker than the pocket portion 2.

On the other hand, the cover film 4 is made of an opaque material (such as aluminum foil) with a sealant made of, for example, polypropylene resin, etc., applied to its surface.

The PTP sheet 1 is manufactured by punching out a strip-shaped PTP film 6 (see FIG. 3) as a "blister film" formed from a strip-shaped container film 3 and a strip-shaped cover film 4 into a sheet, and is formed into a roughly rectangular shape when viewed from above.

The PTP sheet 1 has two rows of pockets in the short direction, each row consisting of five pockets 2 arranged along the longitudinal direction. In other words, a total of ten pockets 2 are formed. Each pocket 2 contains one tablet 5 as the "contents."

Next, the schematic configuration of the PTP packaging machine 10 for manufacturing the PTP sheet 1 will be described. In this embodiment, the PTP packaging machine 10 corresponds to a "blister packaging machine."

As shown in FIG. 4, at the most upstream side of the PTP packaging machine 10, a strip-shaped original sheet of container film 3 is wound into a roll. The pull-out end side of the rolled container film 3 is guided by a guide roll 13. The container film 3 is hung on an intermittent feed roll 14 downstream 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 forming device 16 are arranged in this order along the transport path of the container film 3. Then, when the container film 3 is heated by the heating device 15 and becomes relatively flexible, a plurality of pockets 2 are formed at predetermined positions of the container film 3 by the pocket forming device 16. The pockets 2 are formed during the intervals between the transport operations of the container film 3 by the intermittent feed roll 14.

The container film 3 sent out from the intermittent feed roll 14 is hung in this order over the tension roll 18, guide roll 19, and film receiving roll 20. The film receiving roll 20 is connected to a motor that rotates at a constant speed, so it transports the container film 3 continuously and at a constant speed. The tension roll 18 pulls the container film 3 toward the tension side by elastic force, preventing slack in the container film 3 due to differences in the transport operations of the intermittent feed roll 14 and the film receiving roll 20, and keeping the container film 3 in a constant tension state.

Between the guide roll 19 and the film receiving roll 20, an inspection device 21, a filling device 22, and a post-filling inspection device 23 are arranged in this order along the transport path of the container film 3.

The inspection device 21 inspects the container film 3 after the pocket portion 2 is formed and before the pocket portion 2 is filled with tablets 5. Details of the inspection device 21 will be described later.

The filling device 22 has the function of filling the pockets 2 with tablets 5. The post-filling inspection device 23 performs inspections to check, for example, whether the tablets 5 are securely contained in each pocket 2, whether there are any abnormalities such as breakage in the tablets 5, etc.

Meanwhile, the original web of cover film 4 formed in a strip shape is wound into a roll on the most upstream side. The pull-out end of the rolled cover film 4 is guided toward the heating roll 25 by the guide roll 24.

The heating roll 25 can be pressed against the film receiving roll 20, and the container film 3 and cover film 4 are fed between the two rolls 20, 25. Then, as the container film 3 and cover film 4 pass between the two rolls 20, 25 in a heated and pressed state, the cover film 4 is attached to the container film 3, and the pocket portion 2 is sealed with the cover film 4. This produces a strip-shaped PTP film 6 with tablets 5 housed in each pocket portion 2.

The PTP film 6 sent out from the film receiving roll 20 is hung in this order on the tension roll 27 and the intermittent feed roll 28. The intermittent feed roll 28 is connected to a motor that rotates intermittently, so it transports the PTP film 6 intermittently. The tension roll 27 pulls the PTP film 6 toward the tensioned side by its elastic force, preventing the PTP film 6 from slackening due to differences in the transport operations of the film receiving roll 20 and the intermittent feed roll 28, and keeping the PTP film 6 in a constant tensioned state.

The PTP film 6 sent out from the intermittent feed roll 28 is hung in the order of tension roll 31 and intermittent feed roll 32. The intermittent feed roll 32 is connected to a motor that rotates intermittently, so it transports the PTP film 6 intermittently. The tension roll 31 pulls the PTP film 6 toward the tension side by elastic force, preventing slack in the PTP film 6 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 an engraving device 34 are disposed in this order along the transport path of the PTP film 6. The slit forming device 33 has the function of forming a separation slit at a predetermined position on the PTP film 6. The engraving device 34 has the function of applying an engraving at a predetermined position on the PTP film 6. Note that the separation slit and engraving are not shown in Figure 1 etc.

The PTP film 6 sent out from the intermittent feed roll 32 is hung on the tension roll 35 and the continuous feed roll 36 in that order downstream. 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 the function of punching out the outer edge of the PTP film 6 into PTP sheet units, in other words, the function of cutting off the PTP sheet 1 from the PTP film 6.

The PTP sheet 1 obtained by the sheet punching device 37 is transported by the conveyor 39 and temporarily stored in the finished product hopper 40. However, if the inspection device 21 or the post-filling inspection device 23 determines that the PTP sheet 1 is defective, the PTP sheet 1 determined to be defective is not sent to the finished product hopper 40, but is discharged separately by a defective sheet discharge mechanism (not shown).

A cutting device 41 is disposed downstream of the continuous feed roll 36. The unnecessary film portion 42, which constitutes the strip-shaped remaining material portion (scrap portion) after punching by the sheet punching device 37, is guided to the tension roll 35 and the continuous feed roll 36, and then led to the cutting device 41. The cutting device 41 cuts the unnecessary film portion 42 to a predetermined size. The cut unnecessary film portion 42 (scrap) is stored in a scrap hopper 43 and then disposed of separately.

Next, the inspection device 21 will be described. As shown in Figs. 5 and 6, the inspection device 21 includes a lighting device 51, a camera 52, and an image processing device 53. In this embodiment, the lighting device 51 constitutes the "illumination means", the camera 52 constitutes the "imaging means", and the image processing device 53 constitutes the "determination means".

The lighting device 51 is disposed on the protruding side of the pocket portion 2 of the container film 3. The lighting device 51 has a first light source 51a, a second light source 51b, a third light source 51c, a first half mirror 51d, a second half mirror 51e, and a diffusion plate 51f. Hereinafter, the first light source 51a, the second light source 51b, and the third light source 51c may be referred to as "light sources 51a to 51c."

The first light source 51a irradiates the container film 3 with light (ultraviolet light in this embodiment) of wavelength λ0 (see FIG. 7), whose light transmittance to the camera 52 varies depending on the thickness of the container film 3. FIG. 7 shows the relationship between the wavelength of the light irradiated to the container film 3 and the transmittance of the container film 3 when the thicknesses of the container film 3 are T1, T2, T3, and T4 (T1<T2<T3<T4).

The second light source 51b irradiates the container film 3 with light (ultraviolet light in this embodiment) having a wavelength λ1 (see FIG. 7) that is shorter than the wavelength λ0 and does not pass through the container film 3.

The third light source 51c irradiates the container film 3 with light (ultraviolet light in this embodiment) having a wavelength λ2 (see FIG. 7) that is higher than the wavelength λ0 and completely transmits through the container film 3.

The first half mirror 51d has the function of reflecting the light emitted from the second light source 51b toward the container film 3, while transmitting the light emitted from the first light source 51a.

The second half mirror 51e has the function of reflecting the light emitted from the third light source 51c toward the container film 3, while transmitting the light emitted from the first light source 51a and the second light source 51b.

The diffusion plate 51f diffuses the light emitted from the light sources 51a to 51c. This allows the light emitted from the light sources 51a to 51c to be irradiated almost uniformly over the entire lower surface of the container film 3.

The lighting device 51 configured as described above irradiates the container film 3 with light of wavelength λ0, light of wavelength λ1, and light of wavelength λ2 at the same time. Note that the lighting device 51 in this embodiment does not irradiate the container film 3 with light of a wavelength higher than λ2 or light of a wavelength lower than λ1.

The camera 52 is disposed on the opening side of the pocket portion 2 of the container film 3, and is composed of a camera (e.g., a CCD camera or a CMOS camera) that is sensitive to at least ultraviolet light. The positions of the lighting device 51 and the camera 52 may be interchanged. The camera 52 captures the light of wavelengths λ0, λ1, and λ2 that have passed through the container film 3. The image data obtained by the camera 52 is luminance image data that contains information about the luminance of each pixel.

Now, we will explain the brightness image data obtained. First, when the thicknesses of the container film 3 are T1, T2, T3, and T4 (T1<T2<T3<T4), the relationship between the wavelength of the light irradiated to the container film 3 and the transmittance of the container film 3 is such that the thinner the container film 3, the greater the transmittance even for light with a low wavelength, and the thicker the container film 3, the smaller the transmittance even for light with a high wavelength (see Figure 7).

Therefore, as shown in Figures 8 and 9, when a hole HB occurs in the container film 3, light of wavelengths λ0, λ1, and λ2 passes through the hole HB, so the total amount of light received by the camera 52 relating to the hole HB becomes very large, and the brightness of the hole HB in the brightness image data also becomes very large. Note that the hole HB refers to a relatively small hole called a pinhole, a relatively large hole, a tear, etc.

On the other hand, in thin areas of the container film 3 with a thickness of about T2, such as the pocket portion 2 (particularly the bottom of the pocket portion 2), light of wavelength λ2 is completely transmitted and light of wavelength λ0 is easily transmitted, while light of wavelength λ1 is not transmitted. Therefore, the total amount of light received by the camera 52 in the thin areas (such as the pocket portion 2) is sufficiently small compared to the total amount of light received by the hole portion HB. Therefore, the brightness of the thin areas in the brightness image data is sufficiently small compared to the brightness of the hole portion HB.

In addition, if a foreign object IB (see FIG. 9) is attached to the container film 3, the foreign object IB transmits very little light of wavelengths λ0, λ1, and λ2, so the total amount of light received by the camera 52 relating to the foreign object IB becomes very small, and the brightness of the foreign object IB in the brightness image data also becomes very small. Note that examples of the foreign object IB include light-blocking foreign objects that do not transmit light of wavelengths λ1 or more and λ2 or less.

On the other hand, in thick portions of the container film 3, such as the flange portion 3a, which has a thickness of about T3, the light of wavelengths λ0 and λ2 passes through, so the total amount of light received by the camera 52 from the thick portions (such as the flange portion 3a) is sufficiently large compared to the total amount of light received from the foreign body IB. Therefore, the brightness of the thick portions in the brightness image data is sufficiently large compared to the brightness of the foreign body IB.

In this way, in the brightness image data, the brightness difference between the hole HB and the thin portion of the container film 3 (pocket portion 2), and the brightness difference between the foreign body IB and the thick portion of the container film 3 (flange portion 3a) are both sufficiently large (see Figure 9).

The luminance image data obtained by the camera 52 is converted into a digital signal inside the camera 52, and then transferred in the form of a digital signal to the image processing device 53 (particularly the image acquisition unit 53e described below) and stored therein.

The image processing device 53 is composed of a computer including a CPU (Central Processing Unit) that executes predetermined calculation processes, a ROM (Read Only Memory) that stores various programs and fixed value data, a RAM (Random Access Memory) that temporarily stores various data when executing various calculation processes, and peripheral circuits for these.

As shown in FIG. 5, the image processing device 53 functions as various functional units such as a main control unit 53a, a lighting control unit 53b, a camera control unit 53c, a display control unit 53d, an image acquisition unit 53e, and a determination unit 53f, as described below, by the CPU operating in accordance with various programs.

However, the various functional units are realized by the cooperation of various hardware such as the CPU, ROM, and RAM, and there is no need to clearly distinguish between functions realized by hardware and functions realized by software, and some or all of these functions may be realized by hardware circuits such as ICs.

The image processing device 53 further includes an input unit 531 consisting of a keyboard, mouse, touch panel, etc., a display unit 532 consisting of an LCD display or the like and equipped with a display screen capable of displaying various information, a memory unit 533 capable of storing various data, programs, calculation results, inspection results, etc., and a communication unit 534 capable of transmitting and receiving various data to and from the outside.

First, before describing the various functional units that make up the image processing device 53, we will explain the display unit 532, memory unit 533, and communication unit 534.

The display unit 532 is configured to be capable of displaying various information stored in the memory unit 533. Therefore, the display unit 532 can display the brightness image data obtained by the camera 52, the brightness threshold value used for the pass/fail judgment (for example, the brightness L1, L4, etc. described later), the pass/fail judgment result of the container film 3, etc.

The storage unit 533 is composed of a hard disk drive (HDD) or a solid state drive (SSD), and stores, for example, luminance image data and the result of the pass/fail judgment of the container film 3. The storage unit 533 also stores luminance L1, L4, which are luminance thresholds used in the pass/fail judgment, and information (area identification information) for identifying the areas occupied by the container film 3, the pocket portion 2, and the flange portion 3a in the luminance image data.

The communication unit 534 is equipped with a wireless communication interface conforming to a communication standard such as a wired LAN (Local Area Network) or a wireless LAN, and is configured to be able to transmit and receive various data to and from the outside. For example, the pass/fail judgment result performed by the judgment unit 53f is output to the outside via the communication unit 534.

Next, we will explain in more detail the various functional parts that make up the image processing device 53.

The main control unit 53a is a functional unit that controls the entire inspection device 21, and is configured to be able to send and receive various signals to and from other functional units such as the lighting control unit 53b and the camera control unit 53c.

The lighting control unit 53b is a functional unit that controls the light sources 51a to 51c based on command signals from the main control unit 53a.

The camera control unit 53c is a functional unit that controls the camera 52, and controls the timing of image capture by the camera 52 based on command signals from the main control unit 53a.

The display control unit 53d controls the display content on the display unit 532 based on the information stored in the memory unit 533.

The image acquisition unit 53e is a functional unit for importing luminance image data captured and acquired by the camera 52.

The judgment unit 53f is a functional unit that judges the quality of the container film 3 based on the brightness image data obtained by the camera 52. The judgment unit 53f includes a hole judgment unit 53g, a foreign matter judgment unit 53h, and a thickness judgment unit 53j.

The hole determination unit 53g determines, in the brightness image data obtained by the camera 52, an area with a higher brightness than the brightness threshold value L1 as a hole HB. More specifically, the hole determination unit 53g uses the area identification information stored in the memory unit 533 to identify an area occupied by the container film 3 from the brightness image data, and identifies an area within that area with a higher brightness than the brightness L1. If the area (number of pixels) of the high brightness area is equal to or greater than a predetermined value, the hole determination unit 53g determines that the high brightness area is a hole HB. Note that the brightness L1 is, for example, equivalent to the amount of light received by the camera 52 of "2.9".

The foreign object determination unit 53h determines, in the luminance image data, an area that is lower in luminance than the luminance threshold value L4 as a foreign object IB. More specifically, the foreign object determination unit 53h uses the area identification information to identify an area occupied by the container film 3 from the luminance image data, and identifies an area within that area that is lower in luminance than the luminance L4. If the area (number of pixels) of the low-luminance area is equal to or greater than a predetermined value, the foreign object determination unit 53h then determines that the low-luminance area is a foreign object IB. Note that the luminance L4 is, for example, equivalent to the amount of light received by the camera 52 of "0.1".

The thickness determination unit 53j determines whether the thickness of the container film 3 is good or bad based on the brightness of the region between brightness L4 and brightness L1 in the brightness image data. The thickness determination unit 53j includes a pocket thickness determination unit 53k and a flange thickness determination unit 53m.

The pocket thickness determination unit 53k determines whether the thickness of the pocket 2 is good or bad based on the luminance of the area corresponding to the pocket 2 in the luminance image data. More specifically, the pocket thickness determination unit 53k uses the area identification information to identify the area occupied by the pocket 2 (for example, the area occupied by the bottom of the pocket 2) from the area of luminance L4 or more and luminance L1 or less in the luminance image data. The pocket thickness determination unit 53k then calculates the area (number of pixels) of the area in the identified area whose luminance is not within a first luminance range set in advance. If the calculated area is equal to or greater than a predetermined value, the pocket thickness determination unit 53k determines the thickness of the pocket 2 as "bad". On the other hand, if the calculated area is less than the predetermined value, the pocket thickness determination unit 53k determines the thickness of the pocket 2 as "good". The first luminance range refers to, for example, a range that is equal to or greater than the luminance corresponding to the amount of light received by the camera 52 of "1.8" and equal to or less than the luminance corresponding to the amount of light received by the camera 52 of "2.0".

The flange thickness determination unit 53m determines whether the thickness of the flange portion 3a is good or bad based on the brightness of the area corresponding to the flange portion 3a in the brightness image data. More specifically, the flange thickness determination unit 53m uses the area identification information to identify the area occupied by the flange portion 3a from the area of the brightness image data that is equal to or higher than L4 and equal to or lower than L1. The flange thickness determination unit 53m then calculates the area (number of pixels) of the area in the identified area that does not fall within a second brightness range that has been set in advance. If the calculated area is equal to or higher than a predetermined value, the flange thickness determination unit 53m determines the thickness of the flange portion 3a to be "bad". On the other hand, if the calculated area is less than the predetermined value, the flange thickness determination unit 53m determines the thickness of the flange portion 3a to be "good". The second brightness range refers to a range that is equal to or higher than the brightness corresponding to the amount of light received by the camera 52 of "1.0" and equal to or lower than the brightness corresponding to the amount of light received by the camera 52 of "1.2".

As described above in detail, according to this embodiment, the brightness difference between the hole HB and the thin portion of the container film 3 can be made sufficiently large in the brightness image data. This allows the hole determination unit 53g to determine the presence or absence of the hole HB in a manner that is sufficiently distinct from the thin portion of the container film 3. In addition, the thickness determination unit 53j (pocket thickness determination unit 53k) can determine the quality of the thickness of the thin portion of the container film 3 in a manner that is sufficiently distinct from the hole HB. This allows the presence or absence of the hole HB to be more reliably distinguished from the quality of the thickness of the thin portion of the container film 3.

Furthermore, according to this embodiment, the brightness difference between the foreign object IB and the thick portion of the container film 3 can be made sufficiently large in the brightness image data. Therefore, the foreign object determination unit 53h can determine the presence or absence of a foreign object IB in a manner that is sufficiently distinguished from the thick portion of the container film 3. Furthermore, the thickness determination unit 53j (flange thickness determination unit 53m) can determine the pass/fail of the thickness of the thick portion of the container film 3 in a manner that is sufficiently distinguished from the foreign object IB. This makes it possible to more reliably distinguish and detect the presence or absence of a foreign object IB from the pass/fail of the thickness of the thick portion of the container film 3.

Furthermore, since only one camera 52 is required, it is possible to miniaturize the inspection device 21 and reduce costs associated with manufacturing the inspection device 21, etc.

The present invention is not limited to the above embodiment, and may be implemented, for example, as follows. Of course, other applications and modifications not exemplified below are also possible.

(a) In the above embodiment, the lighting device 51 is provided with a second light source 51c, and is configured to irradiate the container film 3 with light of wavelength λ2 from the second light source 51c. In contrast, as shown in FIG. 10, the second light source 51c may not be provided (omitted), and the light of wavelengths λ0 and λ1 may be irradiated onto the container film 3 at the same time.

In this configuration, when a hole HB occurs in the container film 3, light of wavelengths λ0 and λ1 passes through the hole HB, and the total amount of light received by the camera 52 relating to the hole HB becomes very large (see FIG. 12). Therefore, the brightness of the hole HB in the brightness image data becomes very large.

On the other hand, in a thin portion of the container film 3 having a thickness of about T2, such as the bottom of the pocket portion 2, light of wavelength λ1 does not pass through, and light of wavelength λ0 passes through in an amount according to the thickness of the portion (see FIG. 11). Therefore, the total amount of light received by the camera 52 for the thin portion (such as the pocket portion 2) is sufficiently small compared to the total amount of light received by the hole portion HB (see FIG. 12). As a result, the brightness of the thin portion in the brightness image data is sufficiently small compared to the brightness of the hole portion HB.

Therefore, the hole determination unit 53g can determine the presence or absence of the hole HB in a manner that is sufficiently distinct from the thin-walled portion of the container film 3 (e.g., the bottom of the pocket portion 2). In addition, the thickness determination unit 53j (pocket thickness determination unit 53k) can determine the pass/fail of the thickness of the container film 3 in a manner that is sufficiently distinct from the hole HB. This makes it possible to more reliably distinguish and detect the presence or absence of the hole HB from the pass/fail of the thickness of the container film 3. Note that in the above example, inspection for foreign objects is omitted.

(b) In the above embodiment, the lighting device 51 is configured to irradiate the container film 3 with light of wavelength λ0 using the first light source 51a.

13, the lighting device 51 may be provided with a low-wavelength first light source 51g and a high-wavelength first light source 51h, each of which corresponds to a first light source. That is, the lighting device 51 may be provided with two first light sources 51g and 51h as the first light source. The low-wavelength first light source 51g may irradiate the container film 3 with light (ultraviolet light) having a wavelength λ01 whose light transmittance in the pocket portion 2 varies depending on the thickness of the pocket portion 2, and the high-wavelength first light source 51f may irradiate light (ultraviolet light) having a wavelength λ02 that is higher than the wavelength λ01 and whose light transmittance in the flange portion 3a varies depending on the thickness of the flange portion 3a. That is, the light of wavelengths λ01 and λ02 may be irradiated to the container film 3 as the light of wavelength λ0. In the example shown in FIG. 13, the light emitted from the high-wavelength first light source 51h is reflected toward the container film 3 by the third half mirror 51j, while the light from the low-wavelength first light source 51g passes through the third half mirror 51j and is irradiated onto the container film 3.

When configured as described above, for thin areas of the container film 3 with a thickness of about T2, such as the bottom of the pocket portion 2, light with wavelength λ01 is transmitted in an amount corresponding to the thickness of the pocket portion 2, and light with wavelength λ02, which is a longer wavelength than wavelength λ01, is transmitted (see FIG. 14). Therefore, the brightness of the thin areas (such as the pocket portion 2) in the brightness image data is relatively high (see FIG. 15).

On the other hand, for thick portions of the container film 3, such as the flange portion 3a, which has a thickness of about T3, light of wavelength λ02 passes through in an amount corresponding to the thickness of the flange portion 3a, but light of wavelength λ01, which is shorter than wavelength λ02, does not pass through easily (see FIG. 14). Therefore, the luminance of the flange portion 3a in the luminance image data is relatively small (see FIG. 15).

Therefore, in the brightness image data, the difference between the brightness of the pocket portion 2 and the brightness of the flange portion 3a can be made relatively large. As a result, the pocket thickness determination unit 53k can more accurately determine whether the thickness of the pocket portion 2 is good or bad, while being sufficiently distinguished from the flange portion 3a. Furthermore, the flange thickness determination unit 53m can more accurately determine whether the thickness of the flange portion 3a is good or bad, while being sufficiently distinguished from the pocket portion 2. This can further increase the accuracy of the pass/fail determination of the thicknesses of the pocket portion 2 and the flange portion 3a.

(c) In the above embodiment, the lighting device 51 is configured to irradiate light of wavelengths λ0, λ1, and λ2 by multiple light sources 51a, 51b, and 51c. In contrast, the lighting device may be equipped with a light source (e.g., a lamp light source) that irradiates light of multiple wavelengths at once, and a bandpass filter that adjusts the wavelength of the light irradiated from the light source to the container film 3. In this case, the bandpass filter may be configured to irradiate the container film 3 with light containing each of the wavelengths λ0, λ1, and λ2 (or wavelengths λ0 and λ1) (i.e., light containing light of multiple wavelengths) at once, or to irradiate only the light of wavelengths λ0, λ1, and λ2 (or wavelengths λ0 and λ1) at once. In addition, the lighting device may be configured to irradiate the container film 3 with white light containing each of the wavelengths λ0, λ1, and λ2 (or wavelengths λ0 and λ1).

Of course, the camera configuration (e.g. light sensitivity) may be changed as appropriate to suit the lighting device.

(d) In the above embodiment, tablets 5 are given as the "contents," but the contents are not limited to tablets.

The type and shape of the tablets are not limited to those described in the above embodiment. For example, tablets include not only medicines but also tablets used for eating and drinking. Tablets include plain tablets, sugar-coated tablets, film-coated tablets, enteric-coated tablets, and gelatin-coated tablets, as well as various capsule tablets such as hard capsules and soft capsules.

Furthermore, the shape of the tablet may not only be circular when viewed from above, but may also be, for example, polygonal, elliptical, or oval when viewed from above.

(e) The configuration of the PTP sheet to be manufactured is not limited to the above embodiment. For example, the arrangement and number of pocket portions 2 in each PTP sheet unit are not limited to the above embodiment.

In the above embodiment, the PTP film 6 is configured with a number of pockets 2 arranged along its width direction corresponding to one sheet, but this is not limited to this, and for example, the PTP film 6 may be configured with a number of pockets 2 arranged along its width direction corresponding to multiple sheets.

(f) In the above embodiment, the inspection device 21 is applied to the PTP packaging machine 10, but the inspection device 21 may also be applied to a blister packaging machine for manufacturing blister sheets other than the PTP sheet 1.

1... PTP sheet (blister sheet), 2... pocket portion, 3... container film, 3a... flange portion, 4... cover film, 5... tablet (contents), 10... PTP packaging machine (blister packaging machine), 21... inspection device, 51... lighting device (irradiation means), 52... camera (imaging means), 53... image processing device (determination means), 53g... hole determination section (hole determination means), 53h... foreign matter determination section (foreign matter determination means), 53j... thickness determination section (thickness determination means), 53k... pocket thickness determination section (pocket thickness determination means), 53m... flange thickness determination section (flange thickness determination means), IB... foreign matter, HB... hole.

Claims (4)

An inspection device for inspecting a resin container film having a pocket portion for accommodating contents,
An irradiation means for irradiating the container film with a predetermined light;
an imaging means that is provided on the opposite side of the container film from the illumination means and is capable of imaging light that is irradiated by the illumination means and transmitted through the container film to obtain brightness image data;
A determination means for determining whether the container film is good or bad based on the brightness image data obtained by the imaging means,
The irradiation means is configured to irradiate the container film with only light of a wavelength λ0, the transmittance of which varies depending on the thickness of the container film toward the imaging means , and light of a wavelength λ1, the wavelength of which is shorter than the wavelength λ0 and does not pass through the container film, at one time;
The imaging means is configured to be capable of imaging at least light of wavelength λ0 and light of wavelength λ1,
The determination means is
a hole determination means for determining, in the brightness image data obtained by the imaging means, an area having a brightness higher than a predetermined brightness L1 as a hole;
An inspection device characterized by having a thickness determination means for determining whether the thickness of the container film is good or bad based on the brightness of an area in the brightness image data that is below brightness L1. An inspection device for inspecting a resin container film having a pocket portion for accommodating contents,
An irradiation means for irradiating the container film with a predetermined light;
an imaging means that is provided on the opposite side of the container film from the illumination means and is capable of imaging light that is irradiated by the illumination means and transmitted through the container film to obtain brightness image data;
A determination means for determining whether the container film is good or bad based on the brightness image data obtained by the imaging means,
The irradiation means is configured to irradiate the container film with only light of wavelength λ0, the transmittance of which varies depending on the thickness of the container film toward the imaging means, light of wavelength λ1, which is shorter than wavelength λ0 and does not pass through the container film, and light of wavelength λ2, which is longer than wavelength λ0 and completely passes through the container film, at one time;
the imaging means is configured to be capable of imaging at least light of wavelength λ0, light of wavelength λ1, and light of wavelength λ2;
The determination means is
a hole determination means for determining, in the brightness image data obtained by the imaging means, an area having a brightness higher than a predetermined brightness L1 as a hole;
a thickness determination means for determining whether or not the thickness of the container film is good based on the brightness of an area equal to or less than the brightness L1 in the brightness image data; and
the determining means includes a foreign matter determining means for determining, in the luminance image data, an area having a luminance lower than a predetermined luminance L4 as a foreign matter,
The inspection device is characterized in that the thickness determination means is configured to determine whether the thickness of the container film is good or bad based on the brightness of the area in the brightness image data that is between brightness L4 and brightness L1. An inspection device for inspecting a resin container film having a pocket portion for accommodating contents,
An irradiation means for irradiating the container film with a predetermined light;
an imaging means that is provided on the opposite side of the container film from the illumination means and is capable of imaging light that is irradiated by the illumination means and transmitted through the container film to obtain brightness image data;
A determination means for determining whether the container film is good or bad based on the brightness image data obtained by the imaging means,
The irradiation means is configured to simultaneously irradiate the container film with light of a wavelength λ0, the transmittance of which varies toward the imaging means depending on the thickness of the container film, and light of a wavelength λ1, which is shorter than the wavelength λ0 and does not pass through the container film;
The imaging means is configured to be capable of imaging at least light of wavelength λ0 and light of wavelength λ1,
The determination means is
a hole determination means for determining, in the brightness image data obtained by the imaging means, an area having a brightness higher than a predetermined brightness L1 as a hole;
a thickness determination means for determining whether or not the thickness of the container film is good based on the brightness of an area equal to or less than the brightness L1 in the brightness image data;
the container film has a flange portion that is located at an opening periphery of the pocket portion, is thicker than the pocket portion, and is flat;
the irradiation means is configured to irradiate, as the light of wavelength λ0, light of wavelength λ01, the transmittance of which through the pocket portion to the imaging means varies depending on a thickness of the pocket portion, and light of wavelength λ02, which has a wavelength longer than the wavelength λ01 and the transmittance of which through the flange portion to the imaging means varies depending on a thickness of the flange portion;
The thickness determination means is
a pocket thickness determining means for determining whether a thickness of the pocket is good or bad based on the brightness of an area corresponding to the pocket in the brightness image data;
An inspection device characterized by comprising a flange thickness determination means for determining whether the thickness of the flange portion is good or bad based on the brightness of an area corresponding to the flange portion in the brightness image data. The inspection device according to any one of claims 1 to 3 ,
A blister packaging machine that produces a blister sheet in which a cover film is attached to the container film so as to cover the pocket portion while contents are placed in the pocket portion formed in the container film.

Images