Appearance inspection device and PTP packaging machine

Abstract

Provided is a visual inspection device, etc., in which it is possible to perform operations such as inspection of foreign matter adhesion with good accuracy based on image data obtained by a single imaging without performing complicated judgment processing. The visual inspection device (22) includes: an imaging device (53) that can image a container film (3) through an imaging side polarizing plate (53B); a first irradiation device (51) that can irradiate light toward the container film (3); a second irradiation device (52) that can irradiate light from a second light source (52A) through an irradiation side polarizing plate (52B) to the container film (3); and a processing execution device (60) that makes a judgment on whether the foreign matter adhesion is good or not based on the image data obtained by the imaging device (53). The polarization direction of the imaging side polarizing plate (53B) is set in a direction that blocks regular reflected light from the container film (3) side of the light irradiated from the second irradiation device (52). The imaging device (53) images the container film (3) in a state where light is irradiated by both the first irradiation device (51) and the second irradiation device (52).

Description

Technical Field

[0001] The present invention relates to a visual inspection device used in the manufacture of a PTP sheet and a PTP packaging machine having the visual inspection device. Background Art

[0002] Generally, as a blister sheet used in the field of pharmaceuticals, a PTP (blister pack) sheet is known. The PTP sheet includes a container film and a cover film, wherein the container film has a pocket portion for receiving tablets, and the cover film is mounted on the container film in a manner that seals the opening side of the pocket portion.

[0003] PTP sheets can be manufactured by a PTP packaging machine. The PTP packaging machine includes a mechanism for forming a bag portion on a conveyed strip-shaped container film; a mechanism for filling the bag portion with tablets; a mechanism for attaching a strip-shaped cover film to the container film in a manner that seals the opening side of the bag portion; and a mechanism for punching a strip-shaped PTP film composed of a container film and a cover film in units of PTP sheets.

[0004] Furthermore, in the manufacturing process of the PTP sheet, an appearance inspection device is provided, and the appearance inspection device inspects the adhesion of foreign matter to the container film during the period after the tablet is received in the bag portion of the transported container film and before the outer cover film is attached to the container film. The appearance inspection device includes, for example, an irradiation mechanism that irradiates light to the container film side; a camera mechanism that captures the container film irradiated with light; and a good or bad judgment mechanism that performs a good or bad judgment regarding the adhesion of foreign matter based on the image data obtained by the camera mechanism.

[0005] However, in the case where the tablet is a bare chip, when the tablet is filled in the bag, the tablet powder is scattered and adheres to the surrounding part of the bag of the container film. Such tablet powder does not cause any particular problem to the product unless it forms a large mass. However, by using a visual inspection device, the tablet powder is judged as foreign matter in the same way as hair, fiber scraps, etc., and the PTP sheet without a problem is treated as a defective product, which results in a risk of increasing production costs.

[0006] Therefore, a visual inspection device has been proposed, which aims to distinguish between tablet powder and foreign matter attached to a container film (for example, see Patent Document 1). The visual inspection device of Patent Document 1 performs the following operation process.

[0007] First, while irradiating the container film side with light from a predetermined reflection light source, a predetermined liquid crystal shutter is turned on (light shielding state), and then the container film is photographed by a camera mechanism, thereby obtaining a reflection image as a color image. Next, while the reflection light source is turned off and a predetermined transmission light source is turned on, the liquid crystal shutter is turned off (light transmitting state), thereby obtaining a transmission image by photographing the container film by the camera mechanism.

[0008] Furthermore, the obtained reflected image and transmitted image are used to judge whether the foreign matter candidate is a tablet powder based on the color and position of the foreign matter candidate regarded as a foreign matter located on them. That is, when the color of the foreign matter candidate in the reflected image (color image) is the same as the color of the tablet powder, and the position of the foreign matter candidate in the reflected image is the same as the position of the foreign matter candidate in the transmitted image, the foreign matter candidate is judged to be a tablet powder.

[0009] Prior art literature

[0010] Patent Literature

[0011] Patent document 1: WO2015 / 136598 Summary of the invention

[0012] Problems to be solved by the invention

[0013] However, the appearance inspection device of the above-mentioned patent document 1 has the following dangers, namely, (1) the burden of the device's operation processing is heavy; (2) it is difficult to achieve good inspection accuracy and high-speed production of PTP sheets at the same time; (3) the tablet powder is initially mistakenly judged as a foreign matter through the above-mentioned judgment process, and (4) there is a risk of various adverse conditions that make it difficult to actually perform the above-mentioned judgment process.

[0014] First, regarding (1) above, when performing two-dimensional imaging to obtain a transmission image and a reflection image, it is necessary to appropriately operate various devices such as a light source and a liquid crystal shutter. This increases the load of the device operation processing.

[0015] In addition, regarding the above (2), the judgment process based on color and position is relatively complicated. However, it is necessary to reduce the resolution of the appearance inspection device in order to perform such a complicated judgment process while responding to the extremely high-speed (e.g., 8,000 tablets / minute) tablet packaging of the PTP packaging machine. The reduction in resolution leads to a reduction in inspection accuracy. On the other hand, if the resolution is to be maintained to a certain extent, the tablets must be packaged at a low speed, resulting in a reduction in productivity.

[0016] In addition, regarding the above (3), tablets usually include one or more active ingredients, and include various additives such as excipients, binders, and destructive agents, and are not limited to the case where the colors of the active ingredients or the additives are the same. Therefore, even if the color of a foreign matter candidate is different from the color of the tablet, there is still a case where the foreign matter candidate is tablet powder. In addition, since the tablet powder is not fixed on the container film, there is a possibility that the position of the tablet powder in the two images is still changed. Therefore, in the method of judging whether it is tablet powder or foreign matter by comparing color and position, there is a risk of misjudging the tablet powder as a foreign matter.

[0017] In addition, regarding the above (4), the container film is usually transported at high speed while being accompanied by vibration. However, it is actually difficult to determine the sameness of the position of the foreign matter candidate in the reflected image and the transmitted image obtained by the second camera while switching the ON and OFF states of the liquid crystal shutter and turning the light source on and off.

[0018] The present invention is proposed in view of the above situation, and its purpose is to provide an appearance inspection device and a PTP packaging machine that can perform inspection of foreign matter adhesion with good accuracy based on image data obtained through a single camera without performing complicated judgment processing.

[0019] Technical solutions to solve problems

[0020] The following is a description of each technical solution suitable for solving the above-mentioned purpose. In addition, according to the needs, a unique effect is attached to the corresponding technical solution.

[0021] Technical Solution 1. A visual inspection device is used in the following PTP sheet manufacturing process, in which a tablet is received inside a bag formed on a container film, and a cover film is installed on the container film in a manner of closing the bag. In the visual inspection device, after the tablet is received in the bag of the conveyed strip-shaped container film and before the cover film is installed on the container film, an inspection of foreign matter attached to the container film is performed, characterized in that the visual inspection device comprises:

[0022] An imaging mechanism having a predetermined imaging-side polarizing plate, through which the container film can be imaged;

[0023] a first irradiation mechanism, which is disposed on the opposite side of the imaging mechanism via the container film and has a predetermined first light source, and can irradiate light toward the protruding side of the bag portion of the container film through the first light source;

[0024] a second irradiation mechanism having a predetermined second light source and a predetermined irradiation-side polarizing plate, and capable of irradiating light from the second light source through the irradiation-side polarizing plate toward the opening side of the bag portion of the container film;

[0025] a goodness determination unit for determining whether the foreign matter is attached to the device based on the image data obtained by the imaging unit;

[0026] In the imaging side polarizing plate, the polarization direction is set in a direction that blocks regular reflected light from the container film side among the light irradiated from the second irradiation means;

[0027] The imaging means is configured to capture an image of the container film in a state where the container film is irradiated with light by both the first irradiation means and the second irradiation means.

[0028] In addition, "attachment of foreign matter to the container film" also includes the meaning of simply loading the foreign matter on the container film.

[0029] According to the above-mentioned first aspect, the container film irradiated with light by both the first irradiation means and the second irradiation means is imaged by the imaging means.

[0030] Here, when light is irradiated only from the first irradiation means, transmitted light from the portion other than the portion where the tablet powder and foreign matter are located in the container film enters the imaging means. Therefore, in the image data obtained in this case, the portion where the tablet powder and foreign matter are located are respectively displayed as dark portions.

[0031] In contrast, when light is irradiated only from the second irradiation mechanism, since foreign matter (hair, lint, etc.) has a smoother surface than the tablet powder, the irradiated light is basically scattered by the tablet powder and is regularly reflected by the foreign matter. In addition, since the polarization direction of the imaging side polarizing plate is set in a direction that blocks the regularly reflected light from the container film side of the light irradiated from the second irradiation mechanism, the amount of scattered reflected light from the tablet powder passing through the imaging side polarizing plate increases, while the amount of regularly reflected light from the foreign matter passing through the imaging side polarizing plate decreases. Therefore, in the image data obtained in this case, the portion where the tablet powder is located is represented as a bright portion, and the portion where the foreign matter is located is represented as a dark portion.

[0032] In the case where light is irradiated from only one of the two irradiation mechanisms, the above-mentioned image data are obtained respectively, and in the case where light is irradiated from both of the two irradiation mechanisms, since the portion where the tablet powder is located in the obtained image data is in a state where the dark portion of the first irradiation mechanism and the bright portion of the second irradiation mechanism overlap, the result is that it is represented as a bright portion. On the other hand, in the obtained image data, since the portion where the foreign matter is located is in a state where the dark portion of the first irradiation mechanism and the bright portion of the second irradiation mechanism overlap, the result is that it is represented as a dark portion. Therefore, in the obtained image data, only the portion where the foreign matter is located is clearly represented as a dark portion, and the portion where the tablet powder is located is almost not represented (the same as the bright portion around it). Therefore, there is no need to perform complicated judgment processing to determine whether it is a tablet powder or a foreign matter, and the inspection can be performed by ignoring the tablet powder based on the obtained image. Therefore, the inspection of foreign matter can be performed with good accuracy.

[0033] Furthermore, since there is no need to perform complicated judgment processing for distinguishing tablet powder from foreign matter, the resolution of the appearance inspection device can be fully improved while responding to the high-speed packaging of tablets. Thus, good inspection accuracy and high-speed production of PTP sheets can be achieved at the same time.

[0034] Furthermore, according to the above-mentioned technical solution 1, when obtaining image data for inspection, the container film irradiated with light by two irradiation means can be imaged only once. This can reduce the load of operation processing of the device.

[0035] Furthermore, it is preferable that the first irradiation means irradiates diffuse light. Therefore, for example, the first irradiation means may be configured so that a predetermined diffusion plate is provided, and diffuse light is irradiated from the first light source toward the container film through the diffusion plate. Furthermore, the first irradiation means may be configured so that a plurality of first light sources composed of LEDs are evenly arranged.

[0036] Technical Solution 2. The appearance inspection device according to Technical Solution 1 is characterized in that the above-mentioned goodness judgment mechanism judges whether the attachment of foreign matter is good or not based only on the brightness value of the image data obtained by the above-mentioned imaging mechanism.

[0037] Since foreign matter is represented as a dark part and tablet powder is represented as a bright part in the acquired image data, it is possible to judge whether the attachment of foreign matter is good or not based only on the brightness value as in the above-mentioned technical solution 2. Therefore, it is not necessary to perform complicated processing (such as specifying the area and shape of the part suspected of being a foreign matter) in order to specify whether it is a foreign matter, and it is possible to reduce the processing burden of the inspection and speed up the inspection.

[0038] Technical solution 3. The appearance inspection device according to technical solution 1 or 2 is characterized in that the above-mentioned good or bad judgment mechanism can perform:

[0039] a first good or bad judgment, wherein the first good or bad judgment is a good or bad judgment based on image data obtained by photographing the container film in a state where the container film is irradiated with light by both the first irradiation mechanism and the second irradiation mechanism by the imaging mechanism;

[0040] a second goodness determination, wherein the second goodness determination is a goodness determination based on image data obtained by photographing the container film in a state where the container film is irradiated with light by one of the first irradiation means and the second irradiation means by the imaging means;

[0041] The above-mentioned goodness / non-compliance judgment means is configured to be capable of performing a selected goodness / non-compliance judgment between the above-mentioned first goodness / non-compliance judgment and the above-mentioned second goodness / non-compliance judgment.

[0042] According to the third technical solution, the goodness judgment mechanism can respectively perform the following one goodness judgment (first goodness judgment) and the following another goodness judgment (second goodness judgment), wherein the one goodness judgment (first goodness judgment) is based on the image data obtained in the state where light is irradiated by both of the two irradiation mechanisms (i.e., image data in the state where tablet powder is hardly represented), and the other goodness judgment (second goodness judgment) is based on the image data obtained in the state where light is irradiated by one of the two irradiation mechanisms (i.e., image data representing the state of tablet powder). In addition, the goodness judgment mechanism can perform one of the first goodness judgment and the second goodness judgment, for example, selected by the user. Thus, for example, when it is intended to perform an inspection in a manner that does not take tablet powder into consideration, the first goodness judgment can be selected, and when it is intended to perform an inspection in a manner that takes tablet powder (e.g., the size of tablet powder, etc.) into consideration, the second goodness judgment can be selected. Thus, while expanding the inspection items of the inspection method, it is possible to suppress the increase in cost by not separately providing a device for performing each goodness judgment.

[0043] Technical Solution 4. The appearance inspection device according to any one of Technical Solutions 1 to 3 is characterized in that the polarization direction of the imaging-side polarizing plate and the polarization direction of the irradiation-side polarizing plate differ by 90 degrees.

[0044] According to the fourth technical solution, the regular reflected light reflected by the foreign matter can be more reliably blocked by the imaging side polarizing plate. Therefore, the location of the foreign matter can be more clearly indicated in the acquired image data, and the foreign matter adhesion can be inspected with better accuracy.

[0045] Technical solution 5. relates to a PTP packaging machine, characterized in that the PTP packaging machine includes an appearance inspection device according to any one of claims 1 to 4.

[0046] According to the above technical solution 5, the same effect as the above technical solution 1 is achieved.

[0047] In addition, the PTP packaging machine, for example, includes: a bag forming mechanism, which forms a bag on the container film conveyed in a strip shape; a filling mechanism, which fills the tablets in the above-mentioned bag; an installation mechanism, which installs a strip-shaped cover film on the above-mentioned container film in a manner of closing the above-mentioned bag; a cutting mechanism, etc., which cuts the strip-shaped PTP film in units of PTP sheets, and installs a strip-shaped cover film on the above-mentioned container film in a manner of closing the above-mentioned bag in the strip-shaped PTP film. In addition, the PTP packaging machine may also include a discharge mechanism, which discharges the PTP sheets determined to be defective by the above-mentioned appearance inspection device. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 is a stereogram showing a PTP sheet;

[0049] Figure 2 It is a partially enlarged cross-sectional view of the PTP sheet;

[0050] Figure 3 is a stereogram showing a PTP film;

[0051] Figure 4 A schematic diagram showing the general structure of a PTP packaging machine;

[0052] Figure 5 A block diagram showing the electrical structure of the appearance inspection device;

[0053] Figure 6 A schematic diagram showing the general structure of a visual inspection device;

[0054] Figure 7 A schematic diagram showing an example of image data obtained in a state where light is irradiated from two lighting devices;

[0055] Figure 8 This is a schematic diagram showing an example of image data obtained in a state where light is irradiated from the first lighting device. DETAILED DESCRIPTION

[0056] An embodiment will be described below with reference to the accompanying drawings. First, the structure of the PTP sheet will be described in detail.

[0057] picture Figure 1 , Figure 2 As shown, the PTP sheet 1 includes a container film 3 and a cover film 4 . The container film 3 has a plurality of pockets 2 . The cover film 4 is mounted on the container film 3 in a manner of closing the pockets 2 .

[0058] The container film 3 of this embodiment is formed of a transparent thermoplastic resin material such as PP (polypropylene) and PVC (polyvinyl chloride) and has light transmittance. On the other hand, the cover film 4 is made of an opaque material (such as aluminum foil), and a sealant such as polyethylene resin is provided on the surface of the opaque material. Obviously, the materials of each film 3, 4 are not limited to these, and other materials can also be used.

[0059] The PTP sheet 1 is manufactured by forming a strip-shaped PTP film 6 (see Figure 3 ) is punched into a sheet shape, and the PTP sheet 1 is roughly rectangular in plan view. On the PTP sheet 1, pocket rows are formed in two rows in the short side direction, and the pocket row is composed of five pockets 2 arranged along its length direction. That is, a total of 10 pockets 2 are formed. In each pocket 2, tablets 5 are received one at a time. The tablets 5 of this embodiment are bare chips that are circular disc-shaped in plan view.

[0060] Refer to the following Figure 4 , the appearance structure of the PTP packaging machine 10 used to manufacture the above-mentioned PTP sheet 1 is described.

[0061] picture Figure 4 As shown, the original roll of the strip-shaped container film 3 is wound in a roll shape at the most upstream side of the PTP packaging machine 10. The extended end of the container film 3 wound in a roll shape is guided to the guide roller 13. The container film 3 is hung on the intermittent conveying roller 14 on the downstream side of the guide roller 13. The intermittent conveying roller 14 is connected to the intermittent conveying motor and conveys the container film 3 in an intermittent manner.

[0062] A heating device 15 and a pocket forming device 16 are sequentially provided between the guide roller 13 and the intermittent conveying roller 14 along the conveying path of the container film 3. In addition, the container film 3 is heated by the heating device 15, and a plurality of pockets 2 are formed at predetermined positions of the container film 3 by the pocket forming device 16 in a relatively soft state of the container film 3. The pockets 2 are formed during the intermittent period between the conveying actions of the container film 3 by the intermittent conveying roller 14. In the present embodiment, the heating device 15 and the pocket forming device 16 constitute a pocket forming mechanism.

[0063] The container film 3 fed from the intermittent feeding roller 14 is sequentially hung on the tension roller 18, the guide roller 19 and the film receiving roller 20. Since the film receiving roller 20 is connected to a motor that rotates to a certain extent, the film receiving roller 20 continuously and at a certain speed feeds the container film 3. The tension roller 18 is in a state of stretching the container film 3 to a side where it is tensioned by elastic force, and prevents the container film 3 from being loosened due to the difference in the feeding actions of the intermittent feeding roller 14 and the film receiving roller 20, and keeps the container film 3 in a tensioned state at ordinary times.

[0064] Between the guide roller 19 and the film receiving roller 20, a tablet filling device 21 and a visual inspection device 22 are sequentially provided along the conveying path of the container film 3. The tablet filling device 21 includes a function as a filling mechanism that automatically fills the tablets 5 into the bag portion 2. The tablet filling device 21 is synchronized with the conveying action of the film receiving roller 20 to the container film 3, and the tablet 5 is dropped by opening the shutter at every predetermined interval, and the tablet 5 is filled into each bag portion 2 with the opening action of the shutter.

[0065] The appearance inspection device 22 performs an inspection for adhesion of foreign matter on the container film 3. The details of the appearance inspection device 22 will be described later.

[0066] On the other hand, the raw material of the cover film 4 formed in a strip shape is wound up on the most upstream side and wound up in a roll shape. The extended end of the cover film 4 wound up in a roll shape is guided to the heating roller 25 by the guide roller 24.

[0067] The heating roller 25 can be pressed against the film receiving roller 20 to feed the container film 3 and the cover film 4 between the two rollers 20 and 25. In addition, the container film 3 and the cover film 4 are passed between the two rollers 20 and 25 in a heated and pressed state, and the cover film 4 is attached to the container film 3, and the bag part 2 is closed by the cover film 4. In this way, the strip-shaped PTP film 6 in which the tablet 5 is received in each bag part 2 is manufactured. In this embodiment, the film receiving roller 20 and the heating roller 25 constitute a mounting mechanism.

[0068] The PTP film 6 fed from the film receiving roller 20 is sequentially hung on the tension roller 27 and the intermittent conveying roller 28. Since the intermittent conveying roller 28 is connected to a motor that rotates intermittently, the PTP film 6 is conveyed intermittently. The tension roller 27 is in a state of pulling the PTP film 6 to one side where it is tensioned by elastic force, preventing the PTP film 6 from being loosened due to the difference in conveying actions between the film receiving roller 20 and the intermittent roller 28, and keeping the PTP film 6 in a tensioned state at ordinary times.

[0069] The PTP film 6 fed from the intermittent transport roller 28 is sequentially hung on the tension roller 31 and the intermittent transport roller 32. Since the intermittent transport roller 32 is connected to a motor that rotates intermittently, the PTP film 6 is intermittently transported. The tension roller 31 is in a state where the PTP film 6 is stretched by elastic force to prevent the PTP film 6 from being loosened between the intermittent transport rollers 28 and 32.

[0070] Between the intermittent conveying roller 28 and the tensioning roller 31, a slit forming device 33 and an imprinting device 34 are sequentially arranged along the conveying path of the PTP film 6. The slit forming device 33 has a function of forming a slit for cutting at a predetermined position of the PTP film 6. In addition, the imprinting device 34 has a function of setting an imprint at a predetermined position (such as a label portion) of the PTP film 6. Figure 1 In the figure, the slits and marks for cutting are omitted.

[0071] The PTP film 6 fed from the intermittent conveying roller 32 is sequentially hung on the tension roller 35 and the continuous conveying roller 36 on its downstream side. A sheet punching device 37 is provided between the intermittent conveying roller 32 and the tension roller 35 along the conveying path of the PTP film 6. The sheet punching device 37 has a function as a sheet punching mechanism for punching the outer edge of the PTP film 6 per PTP sheet 1. In the present embodiment, the sheet punching device 37 constitutes a slitting mechanism.

[0072] The PTP sheets 1 punched by the sheet punching device 37 are transported by the conveyor 39 and temporarily stored in the finished product hopper 40. However, the PTP sheets 1 determined as defective by the appearance inspection device 22 are not transported to the finished product hopper 40, but are discharged separately by a defective sheet discharge mechanism not shown in the figure.

[0073] A cutting device 41 is provided on the downstream side of the above-mentioned continuous conveying roller 36. In addition, the unnecessary film portion 42 constituting the residual portion (discarded portion) remaining in a strip shape after being punched by the sheet punching device 37 is guided to the above-mentioned tensioning roller 35 and the continuous conveying roller 36, and then guided to the cutting device 41. In addition, the above-mentioned continuous conveying roller 36 is pressed by the driven roller, and the unnecessary film portion 42 is conveyed while being clamped. The cutting device 41 cuts the unnecessary film portion 42 into a specified size. The cut unnecessary film portion 42 (discarded portion) is stored in the discard hopper 43 and then separately disposed of.

[0074] In addition, the rollers 14, 20, 28, 31, 32, etc. are located in a positional relationship where the roller surfaces face the bag 2. However, since recesses for receiving the bag 2 are formed on the surfaces of the intermittent conveying rollers 14, etc., the bag 2 is not crushed. In addition, the conveying operation is performed while the bag 2 is received in the recesses of the intermittent conveying rollers 14, etc., thereby reliably performing the intermittent conveying operation and the continuous conveying operation.

[0075] In addition, in the PTP packaging machine 10 of the present embodiment, the tablets 5 are packaged at a very high speed (for example, 800 tablets / minute).

[0076] Next, the appearance inspection device 22 is described. The appearance inspection device 22 performs an inspection of the attachment of foreign matter to the container film 3 (especially the part that finally constitutes the PTP sheet 1) at the following stage, which refers to the stage after the tablet 5 is received in the bag portion 2 of the conveyed belt-shaped container film 3 and before the cover film 4 is attached to the container film 3.

[0077] Appearance inspection device 22 Figure 5 and Figure 6 As shown, it includes a first lighting device 51, a second lighting device 52, a camera device 53, and a processing execution device 60. In this embodiment, the first lighting device 51 is equivalent to the first lighting mechanism, the second lighting device 52 is equivalent to the second lighting mechanism, the camera device 53 is equivalent to the imaging mechanism, and the processing execution device 60 is equivalent to the goodness judgment mechanism.

[0078] The first lighting device 51 includes a first light source 51A disposed below the transported container film 3 and composed of, for example, an LED capable of emitting infrared light, and a diffusion plate 51B disposed between the first light source 51A and the container film 3 and composed of, for example, a slide glass. The first lighting device 51 irradiates diffused light toward the protruding side of the bag portion 2 in the container film 3.

[0079] The second lighting device 52 includes a second light source 52A and a predetermined irradiation side polarizing plate 52B. The second light source 52A is arranged above the container film 3 being transported, and the second light source 52A is composed of, for example, an LED that can irradiate light such as infrared light. The second lighting device 52 irradiates light from the second light source 52A toward the side of the opening of the bag portion 2 in the container film 3 through the irradiation side polarizing plate 52B. The light that has passed through the irradiation side polarizing plate 52B is polarized light that vibrates only in a predetermined direction. In addition, if the type satisfies the condition that the light irradiated from the second light source 52A passes through the irradiation side polarizing plate 52B and irradiates the container film 3, the positional relationship between the second light source 52A and the irradiation side polarizing plate 52B can be appropriately changed. Therefore, for example, the second light source 52A and the irradiation side polarizing plate 52B can be separated.

[0080] The imaging device 53 is disposed on the opposite side of the first lighting device 51 via the container film 3, and includes a camera 53A and an imaging-side polarizing plate 53B. In this embodiment, the camera 53A uses a CCD sensor that is sensitive to at least infrared light. Obviously, this is not limited to this, and a CMOS camera may also be used.

[0081] When the camera 53A irradiates the container film 3 with light emitted from the lighting devices 51 and 52, the camera 53A captures a two-dimensional image of the container film 3 through the imaging side polarizing plate 53B. The image data (brightness image data) obtained by the imaging of the camera 53A is converted into a digital signal (image signal) inside the camera 53A, and then input into the processing execution device 60 in the form of a digital signal. The imaging range of the camera 53A is set to a range that can accommodate at least one PTP sheet (in this embodiment, a plurality of sheets).

[0082] The imaging side polarizing plate 53B is interposed between the camera 53A and the container film 3, and sets a polarization direction in a direction of shielding regular reflected light from the container film 3 side in the light irradiated from the second lighting device 52. That is, the polarization direction of the imaging side polarizing plate 53B differs from the polarization direction of the irradiation side polarizing plate 52B by a predetermined angle or more (for example, 45 degrees or more), and in the present embodiment, the polarization direction of the imaging side polarizing plate 53B differs from the polarization direction of the irradiation side polarizing plate 52B by 90 degrees.

[0083] By setting the polarization direction of the imaging side polarizing plate 53B in this way, the regular reflected light (light having a polarization direction substantially the same as the polarization direction of the light irradiated from the second illumination device 52) among the reflected light from the container film 3 side of the light irradiated from the second illumination device 52 is blocked by the imaging side polarizing plate 53B, and this light is hardly incident on the camera 53A. On the other hand, the scattered reflected light (light having a polarization direction different from the polarization direction of the light irradiated from the second illumination device 52) among the reflected light from the container film 3 side of the light irradiated from the second illumination device 52 passes through the imaging side polarizing plate 53B and is incident on the camera 53A.

[0084] The positional relationship between the camera 53A and the imaging side polarizing plate 53B is not particularly limited as long as it satisfies the condition that the container film 3 is imaged by the camera 53A through the imaging side polarizing plate 53B. Thus, for example, the camera 53A and the imaging side polarizing plate 53B are further separated.

[0085] The processing execution device 60 is composed of a so-called computer system including a CPU as a computing mechanism, a ROM storing various programs, a RAM temporarily storing various data such as computing data and input / output data, etc. The processing execution device 60 includes an image memory 61, an inspection result storage device 62, a judgment memory 63, an image and inspection condition storage device 64, an imaging timing control device 65, an illumination control device 66, and a CPU and input / output interface 67.

[0086] The image memory 61 stores the image data obtained by the camera 53A. Inspection is performed based on the image data stored in the image memory 61. Obviously, the image can also be processed when the inspection is performed. For example, it is considered to perform processing such as masking processing and shading compensation. The purpose of shading compensation is to compensate for the uneven brightness of light caused by different positions because the light of the irradiation devices 51 and 52 evenly irradiates the entire imaging range of the container film 3, etc. In addition, the binary image data obtained by binarizing the image data, the masked image data obtained by performing masking, etc. are also stored in the image memory 61.

[0087] The inspection result storage device 62 stores data on whether the inspection result is good or not, statistical data obtained by processing the data in a probabilistic statistical manner, and the like.

[0088] The judgment memory 63 is used to store various information used for inspection. Various information includes judgment criteria (thresholds, etc.) for judging whether something is good or not, binarization thresholds for binarization processing, data for dividing the range of the inspection object (for example, information for specifying the tablet 5 part in the image data, design data related to the relative positional relationship between the outer edge of the PTP sheet 1 and the bag part 2, etc.). In this embodiment, the brightness threshold, area reference value, etc., which are the above-mentioned judgment criteria, are stored. The brightness threshold is used for judging whether something is good or not based on brightness. The area reference value is used for judging whether something is good or not based on area. In this embodiment, suitable values ​​stored in advance are stored for the brightness threshold and the area reference value.

[0089] The image and inspection condition storage device 64 is composed of, for example, a hard disk device, and stores the date and time used for failure determination, inspection conditions, and the like.

[0090] The imaging timing control device 65 controls the imaging timing of the camera 53A. The imaging timing is controlled based on a signal from an encoder (not shown) provided in the PTP packaging machine 10, and the camera 53A performs imaging every time the container film 3 is conveyed by a predetermined amount.

[0091] The lighting control device 66 controls the operation of the first lighting device 51 and the second lighting device 52. In the present embodiment, the lighting control device 66 controls the two lighting devices 51 and 52 in such a manner that the two lighting devices 51 and 52 are respectively operated when performing the first good or bad judgment described later. On the other hand, the lighting control device 66 controls the two lighting devices 51 and 52 in such a manner that only the first lighting device 51 is operated and the second lighting device 52 is in an off state when performing the second good or bad judgment described later.

[0092] The CPU and input / output interface 67 performs various controls on the appearance inspection device 22. The CPU and input / output interface 67 can send and receive signals between the CPU and the structural devices of the PTP packaging machine 10. Thus, it is possible to control the operation of the above-mentioned defective sheet discharge mechanism, etc. In addition, the CPU and input / output interface 67 also has a function of sending various data to a predetermined display mechanism (not shown in the figure) such as a display. Through this function, various images, inspection results, etc. can be displayed on the above-mentioned display mechanism.

[0093] The processing execution device 60 performs a good or bad judgment based on the image data obtained by the camera 53A, using the storage content of the judgment memory 63. In the present embodiment, the processing execution device 60 can selectively perform two types of good or bad judgments, namely, a first good or bad judgment and a second good or bad judgment. In the present embodiment, the good or bad judgment performed by the processing execution device 60 is configured so that the good or bad judgment can be switched by operating a predetermined switching device (not shown).

[0094] When performing the first good or bad judgment, the processing execution device 60 performs the good or bad judgment based on the image data obtained by the camera 53A in the following state, which means that the two lighting devices 51 and 52 are respectively operated to illuminate the container film 3 by the two lighting devices 51 and 52. More specifically, the processing execution device 60 first sets the inspection object range of the obtained image data. For example, by performing a predetermined masking process on the obtained image data, the part (sheet part) that finally constitutes the PTP sheet 1 in the area occupied by the container film 3 in the image data except the part where the tablet 5 is stored is set as the inspection object range. In addition, the part of the area occupied by the container film 3 except the part where the bag part 2 is located is also set as the inspection object range.

[0095] Next, the processing execution device 60 determines whether foreign matter such as hair or lint is attached based on the brightness value of each pixel located within the set inspection object range and the brightness threshold value stored in the judgment memory 63. In the present embodiment, when the brightness value of each pixel is greater than the brightness threshold value, there is no foreign matter attached and it is judged as good. When it is not the case, foreign matter is attached and it is judged as bad. In addition, the inspection object range can be divided into a plurality of divisions, and the brightness value of the pixels located in the divisions can be calculated as the value of the original data (for example, the average value, etc.), and the calculated value can be compared with the brightness threshold value, thereby judging whether the attachment of foreign matter is good or not. In addition, the brightness difference between adjacent pixels can be calculated, and the calculated brightness difference can be compared with the brightness threshold value to judge whether it is good or not.

[0096] Also, like Figure 7 As shown, in the image data obtained by operating the two illumination devices 51 and 52 , the area where the tablet powder is located is hardly shown, and only the area where the foreign matter F1 , F2 , and F3 are located is clearly shown as a dark area. The reason for this is as follows.

[0097] That is, like Figure 8 As shown, in the image data obtained in the state where only the first lighting device 51 is operated, the foreign matter F1, F2, F3 and the tablet powders K1, K2, K3 are respectively represented as dark areas with low brightness values. On the other hand, in the image data obtained in the state where only the second lighting device 52 is operated, the regular reflected light reflected by the foreign matter F1, F2, F3 hardly enters the camera 53A due to the presence of the imaging side polarizing plate 53B, and the scattered reflected light reflected by the tablet powders K1, K2, K3 enters the camera 53A, so the foreign matter F1, F2, F3 is represented as a dark area, and the tablet powders K1, K2, K3 are represented as a bright area. Therefore, in the image data obtained by operating the two lighting devices 51 and 52 respectively, the area where the tablet powders K1, K2, K3 are located is in a state where the dark area of ​​the first lighting device 51 and the bright area of ​​the second lighting device 52 overlap. As a result, in the image data, the area where the tablet powders K1, K2, and K3 are located is in a state where they constitute a bright area and are hardly displayed. In contrast, in the image data, since the area where the foreign matter F1, F2, and F3 are located is in a state where the dark area of ​​the first lighting device 51 and the dark area of ​​the second lighting device 52 overlap, as a result, they are clearly displayed as a bright area.

[0098] On the other hand, when performing the second good or bad judgment, the processing execution device 60 operates only the first lighting device 51 to illuminate the container film 3 by the first lighting device 51, and then performs the processing based on the image data obtained by the camera 53A (refer to Figure 8), and make a good or bad judgment. More specifically, the processing execution device 60 first uses the above-mentioned binarization threshold stored in the judgment memory 63 to binarize the image data, thereby obtaining binary image data that represents the brightness of each pixel by "0 (dark)" or "1 (bright)". In addition, the processing execution device 60 sets the inspection object range of the obtained binary image data. The setting of the inspection object range is performed in the same way as when performing the first good or bad judgment. Then, block processing is performed with the set inspection object range as the object. In the block processing, the processing of the connected components of the pixels of "0 (dark)" in the binary image data is specified, and the area (the number of pixels in this embodiment) of the specified connected components (block processing) is calculated. Then, based on the block area and the above-mentioned area reference value stored in the judgment memory 63, it is judged whether foreign matter such as hair or fiber scraps, large tablet powder, etc. are attached to the container film 3. In this embodiment, when the area of ​​each block portion is smaller than the above-mentioned area reference value, in particular, if there is no problem of adhesion of foreign matter or large tablet powder, it is judged as good, and otherwise it is judged as bad.

[0099] When the first and second quality judgments are performed, they can be performed based on the image data obtained, corresponding to the inspection of the presence or absence of defects related to the tablet 5 (for example, cracking of the tablet 5, mixing of tablet 5 fragments, missing tablets, different shapes of tablets 5, etc.). In addition, when the second quality judgment is performed, not only the judgment based on the area but also the judgment based on the shape of the connected component can be performed, or instead of the judgment based on the area, the judgment based on the shape of the connected component can be performed.

[0100] In this way, in the first good or bad judgment, block processing and area comparison are not performed, and the good or bad judgment regarding the attachment of foreign matter can be performed by simply comparing the brightness value of the image data with the brightness threshold. That is, the good or bad judgment regarding the attachment of foreign matter can be performed based on the brightness value among various information obtained from the image data. On the other hand, in the second good or bad judgment, block processing and area comparison are required, but not only foreign matter but also large tablet powder can be detected.

[0101] As described in detail above, according to the present embodiment, in the image data obtained by operating the two lighting devices 51 and 52, only the positions where the foreign objects F1, F2, and F3 are located are clearly indicated, and the positions where the tablet powders K1, K2, and K3 are located are almost not indicated. Therefore, without performing a complicated judgment process to judge whether it is a tablet powder or a foreign object, the inspection can be performed by ignoring the tablet powders K1, K2, and K3 based on the image data obtained. Therefore, the adhesion of foreign objects can be inspected with good accuracy.

[0102] Furthermore, since complicated judgment processing for distinguishing tablet powder from foreign matter is not required, the resolution of the appearance inspection device 22 can be sufficiently improved while responding to high-speed packaging of tablets 5. Thus, good inspection accuracy and high-speed production of PTP sheets 1 can be achieved simultaneously.

[0103] Furthermore, when obtaining image data for inspection, the container film 3 irradiated with light by the two lighting devices 51 and 52 can be imaged in only one pass. This can reduce the load of operation processing of the device.

[0104] In addition, in the first good or bad judgment, the good or bad of the attachment of foreign matter can be judged only based on the brightness value. Therefore, it is not necessary to perform complicated processing (such as specifying the area or shape of the part suspected of being a foreign matter) to specify whether it is a foreign matter, and the processing burden of the inspection can be reduced and the inspection can be accelerated.

[0105] Furthermore, the processing execution device 60 can perform a first goodness judgment based on the goodness of image data obtained in a state where light is irradiated by both the two lighting devices 51 and 52, and a second goodness judgment based on the goodness of image data obtained in a state where light is irradiated by the first lighting device 51. Furthermore, the processing execution device 60 can perform a selected one of the first goodness judgment and the second goodness judgment. Thus, for example, in the case of an inspection in which a method of tablet powder is not considered, the first goodness judgment can be selected, and in the case of an inspection in which a method of tablet powder (for example, the size of tablet powder, etc.) is considered, the second goodness judgment can be selected. Thus, it is possible to suppress an increase in cost without separately providing a device for performing goodness judgment while expanding the selection items of the inspection method.

[0106] In addition, since the polarization direction of the imaging side polarizing plate 53B differs from the polarization direction of the illumination side polarizing plate 52B by 90 degrees, the regular reflected light reflected by the foreign matter can be more reliably blocked by the imaging side polarizing plate 53B. Therefore, in the acquired image data, only the location where the foreign matter is located can be more clearly indicated, and the attachment of foreign matter can be inspected with further good accuracy.

[0107] In addition, the present invention is not limited to the contents of the above-mentioned embodiment, and can be implemented as follows, for example. Obviously, other application examples not listed below and modified examples are also possible.

[0108] (a) In the above-mentioned embodiment, the second judgment on whether the image is good or not is made based on the image data obtained by irradiating light from the first lighting device 51. However, the second judgment on whether the image is good or not may be made based on the image data obtained by irradiating light from the second lighting device 52.

[0109] (b) In the above embodiment, the tablet 5 is a bare tablet (a flat tablet in a disc shape) that is circular when viewed from a plane. However, the type and shape of the tablet are not limited to the above embodiments. For example, the tablet 5 includes tablets used not only for medicine but also for diet. In addition, the tablet includes not only bare tablets but also oral chewable tablets, enteric-coated tablets, etc.

[0110] The shape of the tablet may be, for example, not only a circular shape when viewed from above but also a polygonal shape, an elliptical shape, an oblong shape, etc. when viewed from above.

[0111] (c) The arrangement and number of the pockets 2 in the PTP sheet 1 are not limited to the above-described embodiment (2 rows, 10 pockets). For example, a PTP sheet having various arrangements and numbers, such as a type having 3 rows and 12 pockets, may be used.

[0112] In addition, in the above-mentioned embodiment, the following scheme is formed, wherein, in the PTP film 6, a number of bag portions 2 corresponding to one sheet are arranged along its width direction, but it is not limited to this. For example, the following scheme can also be formed, wherein a number of bag portions 2 corresponding to multiple sheets are arranged along its width direction.

[0113] Description of the label:

[0114] Reference numeral 1 indicates a PTP sheet;

[0115] Reference numeral 2 denotes a bag portion;

[0116] Reference numeral 3 denotes a container film;

[0117] Reference numeral 4 represents a mask;

[0118] Reference numeral 5 indicates a tablet;

[0119] Reference numeral 10 denotes a PTP packaging machine;

[0120] Reference numeral 22 denotes an appearance inspection device;

[0121] Reference numeral 51 denotes a first lighting device (first irradiation mechanism);

[0122] Reference numeral 51A denotes a first light source;

[0123] Reference numeral 52 denotes a second lighting device (second irradiation mechanism);

[0124] Reference numeral 52A denotes a second light source;

[0125] Reference numeral 52B denotes an illumination-side polarizing filter;

[0126] Reference numeral 53 denotes a camera device (camera mechanism);

[0127] Reference numeral 53B denotes a polarizing filter on the imaging side;

[0128] Reference numeral 60 denotes a processing execution device (goodness / badness determination means).

Claims

1. A visual inspection device, the visual inspection device being used in a manufacturing process of a PTP sheet, in which a tablet is received in a pocket formed on a container film, and a cover film is attached to the container film in a manner that closes the pocket, In the appearance inspection device, after the tablet is received in the pocket portion of the conveyed belt-shaped container film and before the cover film is attached to the container film, the adhesion of foreign matter to the container film is inspected. It is characterized in that The appearance inspection device comprises: An imaging mechanism having a predetermined imaging-side polarizing plate, capable of imaging the container film through the imaging-side polarizing plate; a first irradiation mechanism, which is disposed on the opposite side of the imaging mechanism via the container film and has a predetermined first light source, and can irradiate light toward the protruding side of the bag portion of the container film through the first light source; a second irradiation mechanism having a predetermined second light source and a predetermined irradiation-side polarizing plate, capable of irradiating light from the second light source through the irradiation-side polarizing plate toward the opening side of the bag portion of the container film; a goodness determination unit for determining whether the foreign matter is attached to the device based on the image data obtained by the imaging unit; In the imaging side polarizing plate, the polarization direction is set in a direction that blocks regular reflected light from the container film side among the light irradiated from the second irradiation means; The imaging means is configured to capture an image of the container film in a state where the container film is irradiated with light by both the first irradiation means and the second irradiation means. When light is irradiated only from the first irradiation means, the areas where the tablet powder and foreign matter are located are respectively represented as dark areas in the obtained image data, and at the same time, If, in the case where light is irradiated only from the second irradiation means, in the obtained image data, the portion where the tablet powder is located is represented as a bright portion, and the portion where the foreign matter is located is represented as a dark portion, By irradiating light from both the first irradiation mechanism and the second irradiation mechanism, in the obtained image data, the area where the tablet powder is located is represented as a bright area, while on the other hand, the area where the foreign matter is located is represented as a dark area. Thus, the inspection can be performed by ignoring the tablet powder.

2. The appearance inspection device according to claim 1, characterized in that: The above-mentioned goodness / badness judging means performs goodness / badness judging related to the attachment of foreign matter based only on the brightness value of the image data obtained by the above-mentioned imaging means.

3. The appearance inspection device according to claim 1 or 2, characterized in that: The above good judgment institutions can conduct: a first good or bad judgment, wherein the first good or bad judgment is a good or bad judgment based on image data obtained by photographing the container film in a state where the container film is irradiated with light by both the first irradiation means and the second irradiation means by the imaging means; a second goodness determination, wherein the second goodness determination is a goodness determination based on image data obtained by photographing the container film in a state where light is irradiated by one of the first irradiation means and the second irradiation means by the imaging means; The above-mentioned goodness / non-compliance judgment means is configured to be capable of performing a selected goodness / non-compliance judgment between the above-mentioned first goodness / non-compliance judgment and the above-mentioned second goodness / non-compliance judgment.

4. The appearance inspection device according to any one of claims 1 to 3, characterized in that: The polarization direction of the imaging-side polarizing plate and the polarization direction of the irradiation-side polarizing plate differ by 90 degrees.

5. A PTP packaging machine, characterized in that: The PTP packaging machine includes the appearance inspection device according to any one of claims 1 to 4.

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