Inspection device and blister packaging machine

Abstract

The present invention provides an inspection device and the like which can more reliably distinguish and detect the presence or absence of a hole part, the qualification or absence of a container film thickness and the like through a single imaging mechanism. The inspection device (21) is provided with: a camera (52) capable of capturing an image of light that has passed through the container film to obtain brightness image data; and an image processing device (53) that determines whether the container film (3) is qualified or not on the basis of the luminance image data. The illumination device (51) emits, to the container film, light having a wavelength [lambda] 0 in which the transmittance of light emitted to the camera (52) side varies in accordance with the thickness of the container film, and light having a wavelength [lambda] 1 which has a wavelength lower than the wavelength [lambda] 0 and which is impermeable to the container film. The image processing device (53) determines a region having a higher brightness than the brightness (L1) in the brightness image data as a hole portion, and determines whether or not the thickness of the container film is qualified on the basis of the brightness of the region having the brightness (L1) or less in the brightness image data.

Description

Technical Field

[0001] The present invention relates to an inspection device for inspecting a container film made of resin, and a blister packaging machine having the inspection device. Background Art

[0002] There is currently known a PTP (Press Through Package) sheet, which is generally used as a blister sheet in the field of pharmaceuticals. The PTP sheet comprises: a resin container film having a bag portion, the bag portion accommodating contents such as tablets; and a cover film covering the container film in a manner that seals the opening side of the bag portion.

[0003] The blister sheet as described above can be manufactured by a blister packaging machine. The blister packaging machine has a mechanism for forming a bag portion with respect to a conveyed strip-shaped container film, a mechanism for filling the bag portion with a content, a mechanism for covering the strip-shaped cover film on the container film to seal the opening side of the bag portion, and a mechanism for punching the strip-shaped blister film composed of the container film and the cover film into sheets.

[0004] However, during the manufacturing process of the blister sheet, the thickness balance of each portion in the container film may be inadvertently destroyed.

[0005] Therefore, as an inspection device for determining whether a container film is qualified or not, a method for determining whether a container film is qualified or not has been proposed, the method comprising: an irradiation mechanism for irradiating a bag portion with predetermined light; an imaging mechanism for acquiring transmission image data based on light transmitted through the bag portion, and determining whether the container film is qualified or not based on the transmission image data (see Patent Document 1, etc.). In the inspection device, the transmission image data is brightness image data, in which the brightness in each part is different according to the transmittance of light in the container film. By using the brightness of each part in the brightness image data, the thickness of each part of the container film is calculated, and the qualified or not is determined based on the calculated thickness.

[0006] In addition, holes (relatively small holes called pinholes, relatively large holes, tears, etc.) may appear in the container film, and if the bag has holes, the sealing performance of the content will be affected.

[0007] Therefore, an inspection device has been proposed that detects the presence or absence of a hole in a bag portion using the content filled in the bag portion (for example, see Patent Document 2, etc.). The inspection device includes: an irradiation mechanism that irradiates a container film with a predetermined light; and a camera mechanism that is provided on the opposite side of the irradiation mechanism through the container film, and the camera mechanism can capture light that passes through the container film and reflects the content. Furthermore, the presence or absence of a hole can be detected by distinguishing the brightness of the surface of the content based on the image data obtained by the camera mechanism.

[0008] [Prior art literature]

[0009] [Patent Document]

[0010] Patent Document 1: Japanese Patent Application Publication No. 2019-31302

[0011] Patent Document 2: Japanese Patent Application Publication No. 2009-36522 Summary of the invention

[0012] [Problems to be solved by the invention]

[0013] However, holes (pinholes, etc.) have a serious disadvantage in that they impair the sealing of the contents. Therefore, even in the selection of pass / fail and the countermeasures for failure, it is required to distinguish and detect the pass / fail related to the thickness of the container film by the presence or absence of holes.

[0014] In this regard, it is considered that, if simply considered, the presence or absence of holes and the pass / fail status of the container film thickness can be distinguished and detected by using brightness image data as in the inspection device related to Patent Document 1.

[0015] However, in a sufficiently thin portion of the container film, such as the bottom of the bag, the light transmittance can be close to 100%. Therefore, it is difficult to distinguish between a hole portion with a light transmittance of 100% and a sufficiently thin portion of the container film in the brightness image data. Therefore, it may not be possible to distinguish and detect the presence or absence of a hole portion and the pass or fail of the container film thickness using only the brightness image data.

[0016] Therefore, it is considered to provide both an inspection device for determining whether the thickness of the container film is acceptable (for example, the inspection device related to Patent Document 1) and an inspection device for detecting the presence or absence of a hole (for example, the inspection device related to Patent Document 2). However, in this case, at least a plurality of imaging mechanisms need to be provided, which may lead to an increase in the size of the device and an increase in the cost of manufacturing, maintenance, etc.

[0017] The present invention is proposed in view of the above situation, and its purpose is to provide an inspection device, etc., which can more reliably distinguish and detect the presence or absence of holes and the pass or fail of the container film thickness through a camera mechanism, and seek to miniaturize the device and reduce related costs such as manufacturing.

[0018] [Technical solutions to solve the problem]

[0019] Hereinafter, each technical solution suitable for solving the above-mentioned purpose will be described in detail. In addition, as needed, the specific effects of the corresponding technical solution will be noted.

[0020] Technical Solution 1. An inspection device for inspecting a container film made of resin, the container film having a bag portion for storing contents, characterized in that the inspection device comprises:

[0021] an irradiation mechanism for irradiating predetermined light to the container film;

[0022] an imaging mechanism disposed on the opposite side of the container film from the irradiation mechanism via the container film, capable of capturing light irradiated by the irradiation mechanism and transmitted through the container film to obtain brightness image data; and

[0023] A determination mechanism, which determines whether the container film is qualified or not according to the brightness image data obtained by the camera mechanism;

[0024] The irradiation mechanism is configured to irradiate the container film with light of wavelength λ0 and light of wavelength λ1 at once, the light of wavelength λ0 varies in accordance with the thickness of the container film, and the light of wavelength λ1 has a wavelength lower than wavelength λ0 and cannot pass through the container film.

[0025] The camera is configured to capture at least light of wavelength λ0 and light of wavelength λ1.

[0026] The determination mechanism comprises:

[0027] a hole portion judging means for judging, in the brightness image data obtained by the imaging means, a region having a brightness higher than a predetermined brightness L1 as a hole portion; and

[0028] A thickness determination means determines whether the thickness of the container film is acceptable or not based on the brightness of the area in the area having a brightness L1 or less in the brightness image data.

[0029] According to the above technical solution 1, the irradiation means irradiates the container film with light of wavelength λ0 and light of wavelength λ1 at the same time, and the transmittance of the light irradiated to the imaging means side changes according to the thickness of the container film. The wavelength of the light of wavelength λ1 is lower than the wavelength λ0 and cannot pass through the container film. Then, the imaging means captures these lights to obtain brightness image data.

[0030] Here, for the portion where the hole (pinhole, etc.) on the container film is located, both the light of wavelength λ0 and the light of wavelength λ1 can be transmitted, so the brightness in the brightness image data is relatively high. On the other hand, for the thin-walled portion of the container film (such as the bottom of the bag portion, etc.), the light of wavelength λ1 is not transmitted, and the light of wavelength λ0 is transmitted only in an amount corresponding to the thickness of the portion, so the brightness in the brightness image data is relatively small. Therefore, in the brightness image data, the difference between the brightness of the hole and the brightness of the thin-walled portion in the container film can be set to be relatively large.

[0031] As a result, the hole determination mechanism can determine the presence of the hole in a manner sufficiently distinguishable from the thin-walled portion of the container film. In addition, the thickness determination mechanism can determine whether the thickness of the container film is acceptable in a manner sufficiently distinguishable from the hole. Thus, the presence of the hole and the acceptance of the thickness of the container film can be more reliably distinguished and detected.

[0032] Furthermore, since only one imaging mechanism is required, it is possible to reduce the size of the device and reduce the cost associated with manufacturing and the like.

[0033] Technical Solution 2. The inspection device according to Technical Solution 1 is characterized in that the irradiation mechanism is configured to irradiate the container film with light of wavelength λ0 and light of wavelength λ1 and also irradiate light of wavelength λ2, wherein the wavelength of the light of wavelength λ2 is higher than the wavelength λ0 and completely passes through the container film.

[0034] The camera is configured to capture at least light of wavelength λ0, light of wavelength λ1, and light of wavelength λ2.

[0035] The determination means includes a foreign matter determination means, which determines that a region in the brightness image data with a brightness lower than a predetermined brightness L4 is a foreign matter,

[0036] The thickness determination unit is configured to determine whether the thickness of the container film is acceptable or not based on the brightness of the region in the region having a brightness of L4 or more and a brightness of L1 or less in the brightness image data.

[0037] There may be some foreign matter attached to the container film. When the contents are chemicals or food, the presence of foreign matter is a serious hygienic defect. Therefore, even in the selection of qualified and unqualified products and the countermeasures for unqualified products, it is necessary to distinguish and detect the presence of foreign matter from the thickness of the container film.

[0038] In this regard, according to the second technical solution, the irradiation means irradiates the container film with light of wavelength λ0 and light of wavelength λ1, and also irradiates light of wavelength λ2, which has a wavelength longer than wavelength λ0 and completely transmits through the container film. Furthermore, the imaging means captures these lights, thereby obtaining brightness image data.

[0039] Here, with respect to the portion of the container film where the foreign matter (light-shielding foreign matter) is attached, the light of wavelengths λ0, λ1, and λ2 cannot be transmitted at all or almost at all, so the brightness in the brightness image data becomes very small. On the other hand, with respect to the thick-walled portion of the container film (the flange portion of the technical solution 3 described later, etc.), at least the light of wavelength λ2 can be transmitted, so the brightness in the brightness image data becomes relatively large. Therefore, in the brightness image data, the difference between the brightness of the foreign matter and the brightness of the thick-walled portion of the container film can be set to be relatively large.

[0040] As a result, the presence of foreign matter can be determined by the foreign matter determination mechanism in a manner sufficiently distinguishable from the thick wall portion of the container film. In addition, the thickness determination mechanism can also determine the pass / fail status related to the thickness of the container film in a manner sufficiently distinguishable from the foreign matter. Thus, the presence of foreign matter and the pass / fail status related to the thickness of the container film can be more reliably distinguished and detected.

[0041] Technical Solution 3. The inspection device according to Technical Solution 1 is characterized in that the container film has a flat flange portion located at the periphery of the opening of the bag portion, and the flange portion is thicker than the wall of the bag portion.

[0042] The irradiation mechanism is configured to irradiate light of wavelength λ01 and light of wavelength λ02 as light of wavelength λ0, wherein the light of wavelength λ01 causes a change in transmittance of the light irradiated to the camera mechanism side in the bag portion in accordance with the thickness of the bag portion, and the light of wavelength λ02 has a wavelength higher than wavelength λ01, causes a change in transmittance of the light irradiated to the camera mechanism side in the flange portion in accordance with the thickness of the flange portion,

[0043] The thickness determination mechanism comprises:

[0044] a pocket thickness determination unit for determining whether the pocket thickness is acceptable or not based on the brightness of a region corresponding to the pocket in the brightness image data; and

[0045] A flange thickness determination unit is provided for determining whether the flange thickness is acceptable or not based on the brightness of a region corresponding to the flange in the brightness image data.

[0046] According to the third technical solution, the irradiation mechanism irradiates light of wavelength λ01 and light of wavelength λ02 as light of wavelength λ0, the light of wavelength λ01 varies in transmittance of the light irradiated into the bag portion according to the thickness of the bag portion, and the light of wavelength λ02 has a wavelength higher than wavelength λ01, and varies in transmittance of the light irradiated into the flange portion according to the thickness of the flange portion. Furthermore, the imaging mechanism captures these lights to obtain brightness image data.

[0047] Here, for the bag portion, light of wavelength λ01 is transmitted only in an amount corresponding to the thickness of the bag portion, and since light of wavelength λ02 having a wavelength higher than wavelength λ01 is transmitted, the brightness in the brightness image data is relatively large. On the other hand, for the flange portion, although light of wavelength λ02 is transmitted only in an amount corresponding to the thickness of the flange portion, light of wavelength λ01 having a wavelength lower than wavelength λ02 is difficult to transmit, and therefore the brightness in the brightness image data is relatively small. Therefore, in the brightness image data, the difference between the brightness of the bag portion and the brightness of the flange portion can be set to be relatively large.

[0048] As a result, the bag thickness determination mechanism can determine the pass / fail of the thickness of the bag in a manner sufficiently distinguishable from that of the flange. Also, the flange thickness determination mechanism can determine the pass / fail of the thickness of the flange in a manner sufficiently distinguishable from that of the bag. Thus, the accuracy of the pass / fail determination related to the thickness of each of the bag and flange can be improved.

[0049] Technical Solution 4. A blister packaging machine for producing blister sheets, the blister packaging machine having the inspection device described in Technical Solution 1, the blister sheet being constructed such that the contents are contained in the bag portion formed by the container film, and the blister film is covered relative to the container film in a manner to seal the bag portion.

[0050] According to the above technical solution 4, the same effect as the above technical solution 1 can be achieved.

[0051] Furthermore, the technical matters related to the above-mentioned technical solutions can be appropriately combined. For example, the technical matters related to the above-mentioned technical solution 3 can be combined with the technical matters related to the above-mentioned technical solution 2. Furthermore, for example, the technical matters related to at least one of the above-mentioned technical solutions 2 and 3 can be combined with the technical matters related to the above-mentioned technical solution 4. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 It is a three-dimensional diagram showing a PTP sheet.

[0053] Figure 2 This is a partially enlarged cross-sectional view of the PTP sheet.

[0054] Figure 3 It is a three-dimensional diagram showing a PTP film.

[0055] Figure 4 This is a schematic diagram showing the general structure of a PTP packaging machine.

[0056] Figure 5 This is a block diagram showing the general structure of the inspection device.

[0057] Figure 6 This is a schematic diagram showing a rough structure of a lighting device, etc.

[0058] Figure 7 It is a schematic diagram 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 and T4, and the wavelengths λ0, λ1 and λ2 of the light irradiated from the light source.

[0059] Figure 8 This is a table showing the amount of light received in relation to the bag, flange, foreign matter, and hole.

[0060] Fig. 9 is a schematic diagram showing an example of luminance image data.

[0061] Fig.10 It is a schematic diagram showing the general structure of a lighting device, etc. in another embodiment.

[0062] Fig.11 A schematic diagram showing the relationship between the wavelength of irradiated light and the transmittance of the container film when the thickness of the container film is T1, T2, T3 and T4, and the wavelengths λ0, λ1 and λ2 of the light irradiated from the light source in another embodiment.

[0063] Fig.12 A table showing the amount of light received by the flange, the pocket, and the hole in order to illustrate another embodiment.

[0064] Fig.13 It is a schematic diagram showing the general structure of a lighting device, etc. in another embodiment.

[0065] Fig.14 A schematic diagram showing the relationship between the wavelength of irradiated light and the transmittance of the container film when the thickness of the container film is T1, T2, T3 and T4, and the wavelengths λ0, λ1 and λ2 of the light irradiated from the light source in another embodiment.

[0066] Fig.15 A table showing the amount of light received with respect to the flange, the bag, the foreign matter and the hole is provided to illustrate another embodiment. DETAILED DESCRIPTION

[0067] Please refer to the attached Figure 1 First, the structure of the PTP sheet as a "blister sheet" will be described.

[0068] like Figure 1 , Figure 2 As shown, the PTP sheet 1 includes: a container film 3 having a plurality of pockets 2; and a cover film 4 covering the container film 3 in a manner that seals the pockets 2.

[0069] The container film 3 is formed of a transparent thermoplastic resin material such as PP (polypropylene) or PVC (polyvinyl chloride) and has light transmittance. The container film 3 has a relatively small thickness (for example, 120 μm to 300 μm).

[0070] The container film 3 is formed to extend outward from the opening side end of the bag portion 2 and has a flat flange portion 3a to which the cover film 4 is attached. The flange portion 3a has a thicker wall than the bag portion 2.

[0071] On the other hand, the cover film 4 is made of, for example, an opaque material (such as aluminum foil, etc.), and a sealant made of polypropylene resin, etc., is provided on its surface.

[0072] The PTP sheet 1 is formed by forming a strip-shaped PTP film 6 (see FIG. 1 ) as a “blister film” formed of a strip-shaped container film 3 and a strip-shaped cover film 4. Figure 3 ) is manufactured by stamping into a sheet and is roughly rectangular when viewed from above.

[0073] In the PTP sheet 1, a row of five pockets 2 arranged in the longitudinal direction is formed into two rows in the transverse direction. In other words, a total of ten pockets 2 are formed. Each pocket 2 contains one tablet 5 as a content.

[0074] Next, a general structure of a PTP packaging machine 10 for producing the above-mentioned PTP sheet 1 will be described. In the present embodiment, the PTP packaging machine 10 corresponds to a "blister packaging machine".

[0075] like Figure 4 As shown in FIG. 1 , a raw material roll of a strip-shaped container film 3 is wound into a roll shape at the most upstream side of the PTP packaging machine 10. The pull-out end side of the container film 3 wound into a roll shape is guided to a guide roller 13. The container film 3 is hung on an intermittent feed roller 14 on the downstream side of the guide roller 13. The intermittent feed roller 14 is connected to an intermittently rotating motor and intermittently conveys the container film 3.

[0076] Between the guide roller 13 and the intermittent feed roller 14, a heating device 15 and a pocket forming device 16 are sequentially arranged along the conveying path of the container film 3. Then, the heating device 15 heats the container film 3, and the container film 3 becomes relatively soft, and 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 intermittent period of the conveying operation of the container film 3 by the intermittent feed roller 14.

[0077] The container film 3 fed from the intermittent feed roller 14 is sequentially hung on the tension roller 18, the guide roller 19 and the film receiving roller 20. The film receiving roller 20 is connected to a motor that rotates at a constant speed, so that the container film 3 can be fed at a continuous and constant speed. The tension roller 18 is in a state of pulling the container film 3 toward the tension side by elastic force, preventing the container film 3 from being loosened due to the difference in conveying action between the intermittent feed roller 14 and the film receiving roller 20, and keeping the container film 3 in a tensioned state at all times.

[0078] Between the guide roller 19 and the film receiving roller 20 , an inspection device 21 , a filling device 22 and a post-filling inspection device 23 are arranged in sequence along the transport path of the container film 3 .

[0079] The inspection device 21 inspects the container film 3 after the bag portion 2 is formed and before the bag portion 2 is filled with the tablet 5. The inspection device 21 will be described in detail later.

[0080] The filling device 22 has a function of filling the bag portions 2 with tablets 5. The post-filling inspection device 23 performs inspections on, for example, whether the tablets 5 are securely housed in the bag portions 2, and whether abnormalities such as damages of the tablets 5 occur.

[0081] On the other hand, the raw material roll of the cover film 4 formed into a strip shape is wound into a roll shape at the most upstream side. The drawn-out end of the cover film 4 wound into a roll shape is guided to the heating roller 25 side by the guide roller 24 .

[0082] The heated roller 25 can be pressed against the film receiving roller 20, so that the container film 3 and the cover film 4 are fed between the two rollers 20 and 25. Then, the container film 3 and the cover film 4 pass between the two rollers 20 and 25 in a heated and pressed state, and the cover film 4 covers the container film 3, and the bag 2 is sealed with the cover film 4. Thus, a strip-shaped PTP film 6 in which the tablet 5 is accommodated in the bag 2 is manufactured.

[0083] The PTP film 6 fed from the film receiving roller 20 is sequentially mounted on the tension roller 27 and the intermittent feed roller 28. The intermittent feed roller 28 is connected to an intermittently rotating motor, thereby intermittently feeding the PTP film 6. The tension roller 27 is in a state of pulling the PTP film 6 toward the tension side by elastic force, preventing the PTP film 6 from being relaxed due to the difference in the conveying action between the film receiving roller 20 and the intermittent feed roller 28, and keeping the PTP film 6 in a tensioned state at all times.

[0084] The PTP film 6 fed from the intermittent feed roller 28 is sequentially mounted on the tension roller 31 and the intermittent feed roller 32. The intermittent feed roller 32 is connected to an intermittently rotating motor, thereby intermittently feeding the PTP film 6. The tension roller 31 is in a state of pulling the PTP film 6 toward the tightening side by elastic force, thereby preventing the PTP film 6 from being relaxed between the intermittent feed rollers 28 and 32.

[0085] Between the intermittent feed roller 28 and the tension 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. The imprinting device 34 has a function of imprinting at a predetermined position of the PTP film 6. Figure 1 The slits for cutting and the markings are omitted in the illustration.

[0086] The PTP film 6 fed from the intermittent feed roller 32 is sequentially hung on the tension roller 35 and the continuous feed roller 36 on the downstream side thereof. A sheet punching device 37 is provided between the intermittent feed roller 32 and the tension roller 35 along the conveying path of the PTP film 6. The sheet punching device 37 has the function of punching the outer edge of the PTP film 6 in units of PTP sheets 1, that is, the function of cutting the PTP sheet 1 from the PTP film 6.

[0087] The PTP sheets 1 obtained by the sheet punching device 37 are conveyed by the conveyor 39 and temporarily stored in the finished product hopper 40. However, if the PTP sheets 1 are judged as unqualified by the inspection device 21 or the post-filling inspection device 23, the PTP sheets 1 related to the unqualified judgment are not fed into the finished product hopper 40, but are discharged separately by the unqualified sheet discharge mechanism not shown.

[0088] A cutting device 41 is provided on the downstream side of the continuous feed roller 36. The unnecessary film portion 42 constitutes the remaining portion (waste portion) in a strip shape after the sheet punching device 37 punches out. The unnecessary film portion 42 is guided to the cutting device 41 by the tension roller 35 and the continuous feed roller 36. The cutting device 41 cuts the unnecessary film portion 42 into a predetermined size. The unnecessary film portion 42 (waste) after cutting is stored in the waste hopper 43 and is disposed separately.

[0089] Next, the inspection device 21 will be described. Figure 5 and Figure 6 As shown, the inspection device 21 includes an illumination device 51, a camera 52, and an image processing device 53. In this embodiment, the illumination device 51 constitutes an "illumination means", the camera 52 constitutes an "imaging means", and the image processing device 53 constitutes a "determination means".

[0090] The lighting device 51 is arranged on the protruding side of the bag 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 diffuser plate 51f. Hereinafter, the first light source 51a, the second light source 51b and the third light source 51c will also be referred to as "light sources 51a to 51c".

[0091] The first light source 51a irradiates the container film 3 with a wavelength λ0 (see Figure 7) light (ultraviolet light in this embodiment), the light with wavelength λ0 corresponds to the thickness of the container film 3, and the transmittance of the light irradiated to the camera 52 side changes. Figure 7 It 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 films 3 are T1, T2, T3, and T4 (T1 < T2 < T3 < T4), etc.

[0092] The second light source 51b irradiates the container film 3 with light having a wavelength λ1 (refer to Figure 7 ) (ultraviolet light in this embodiment), and the wavelength of this light with wavelength λ1 is lower than the wavelength λ0 and does not pass through the container film 3.

[0093] The third light source 51c irradiates the container film 3 with light having a wavelength λ2 (refer to Figure 7 ) (ultraviolet light in this embodiment), and the wavelength of this light with wavelength λ2 is higher than the wavelength λ0 and can completely pass through the container film 3.

[0094] The first half mirror 51d has the following functions: on the one hand, it reflects the light irradiated from the second light source 51b to the container film 3 side, and on the other hand, it allows the light irradiated from the first light source 51a to pass through.

[0095] The second half mirror 51e has the following functions: on the one hand, it reflects the light irradiated from the third light source 51c to the container film 3 side, and on the other hand, it allows the lights irradiated from the first light source 51a and the second light source 51b to pass through.

[0096] The diffusion plate 51f diffuses the light emitted from the light sources 51a to 51c. Therefore, the lights irradiated from the light sources 51a to 51c irradiate the entire lower surface of the container film 3 in a substantially uniform manner.

[0097] The lighting device 51 configured as described above irradiates the container film 3 with light having a wavelength λ0, light having a wavelength λ1, and light having a wavelength λ2 all at once. Also, in this embodiment, the lighting device 51 does not irradiate the container film 3 with light having a wavelength higher than the wavelength λ2 and light having a wavelength lower than the wavelength λ1.

[0098] The camera 52 is disposed on the opening side of the bag portion 2 of the container film 3 and is composed of at least a camera sensitive to ultraviolet light (such as a CCD camera, a CMOS camera, etc.). Also, the positions of the lighting device 51 and the camera 52 can be interchanged. The camera 52 captures the lights with wavelengths λ0, λ1, and λ2 that pass through the container film 3. The image data obtained by the camera 52 is luminance image data having information about the luminance of each pixel.

[0099] Here, the obtained luminance image data will be described. First, when the thicknesses of the container film 3 are T1, T2, T3, T4 (T1 < T2 < T3 < T4), the relationship between the wavelength of the light irradiated on the container film 3 and the transmittance of the container film 3 is as follows: the smaller the thickness of the container film 3, the relatively larger the transmittance even for light of a low wavelength; the larger the thickness of the container film 3, the relatively smaller the transmittance even for light of a high wavelength (refer to Figure 7 ).

[0100] Therefore, as shown in Figure 8 and Fig. 9 , when a hole portion HB is formed in the container film 3, lights of wavelengths λ0, λ1, and λ2 will pass through the hole portion HB. Therefore, the total amount of light received by the camera 52 related to the hole portion HB becomes very large, and the luminance of the hole portion HB in the luminance image data also becomes very large. Also, the hole portion HB refers to a relatively small hole called a pinhole, a relatively large hole, a tear, etc.

[0101] On the other hand, in a thin-wall portion of the container film 3 with a thickness of around T2, such as the bag portion 2 (especially the bottom of the bag portion 2), light of wavelength λ2 completely passes through, and at the same time, light of wavelength λ0 easily passes through, while light of wavelength λ1 does not pass through. Therefore, the total amount of light received by the camera 52 related to the thin-wall portion (such as the bag portion 2) becomes very small compared to the total amount of light received related to the hole portion HB. Therefore, the luminance of the thin-wall portion in the luminance image data becomes sufficiently small compared to the luminance of the hole portion HB.

[0102] Also, when a foreign object IB (refer to Fig. 9 ) adheres to the container film 3, in the foreign object IB, lights of wavelengths λ0, λ1, and λ2 can hardly pass through. Therefore, the total amount of light received by the camera 52 related to the foreign object IB becomes very small, and the luminance of the foreign object IB in the luminance image data also becomes very small. Also, as the foreign object IB, examples can include a light-shielding foreign object through which light with a wavelength of λ1 or more and λ2 or less hardly passes.

[0103] On the other hand, in a thick-wall portion of the container film 3 with a thickness of about T3, such as the flange portion 3a, lights of wavelengths λ0 and λ2 can pass through. Therefore, the total amount of light received by the camera 52 related to the thick-wall portion (such as the flange 3a) becomes sufficiently large compared to the total amount of light received related to the foreign object IB. Therefore, the luminance of the thick-wall portion in the luminance image data becomes sufficiently large compared to the luminance of the foreign object IB.

[0104] Thus, in the luminance image data, the luminance difference between the hole portion HB and the thin-wall portion (bag portion 2) of the container film 3, and the luminance difference between the foreign object IB and the thick-wall portion (flange portion 3a) of the container film 3 respectively become sufficiently large (refer to Fig. 9 ).

[0105] The brightness image data acquired by the camera 52 is converted into a digital signal inside the camera 52, and then transmitted to the image processing device 53 (particularly, the image acquisition unit 53e described later) in the form of a digital signal and stored.

[0106] The image processing device 53 is composed of a computer, etc., which includes: a CPU (central processing unit) that performs specified calculations, a ROM (read-only memory) that stores various programs and fixed value data, etc., a RAM (random access memory) that temporarily stores various data when various calculations are performed, and their peripheral circuits, etc.

[0107] like Figure 5 As shown, in the image processing device 53, the CPU operates according to various programs, thereby functioning as various functional units such as the main control unit 53a, the lighting control unit 53b, the camera control unit 53c, the display control unit 53d, the image acquisition unit 53e, and the determination unit 53f described later.

[0108] However, the above-mentioned various functional units are realized through the cooperation of various hardware such as the above-mentioned CPU, ROM, RAM, etc., and there is no need to clearly distinguish between functions implemented by hardware and functions implemented by software. Some or all of these functions can be realized through hardware circuits such as integrated circuits.

[0109] In addition, the image processing device 53 is provided with: an input unit 531 composed of a keyboard, a mouse, a touch screen, etc., a display unit 532 composed of a liquid crystal display, etc. and having a display screen capable of displaying various information, a storage unit 533 capable of storing various data, programs, calculation results, detection results, etc., and a communication unit 534 capable of sending and receiving various data to the outside.

[0110] First, before explaining the various functional units constituting the image processing device 53 , the display unit 532 , the storage unit 533 , and the communication unit 534 will be described.

[0111] The display unit 532 is configured to be able to display various information stored in the storage unit 533. Therefore, the display unit 532 can display brightness image data obtained by the camera 52, brightness thresholds for pass / fail determination (for example, brightness L1, L4, etc. described later), pass / fail determination results of the container film 3, and the like.

[0112] The storage unit 533 is composed of an HDD (hard disk drive), an SSD (solid state drive), etc., and stores, for example, brightness image data and a pass / fail determination result of the container film 3. The storage unit 533 also stores brightness L1 and L4 as brightness thresholds used for pass / fail determination, and information for specifying the area occupied by the container film 3, the bag portion 2, and the flange portion 3a in the brightness image data (area specifying information).

[0113] The communication unit 534 is configured to have a wireless communication interface that complies with communication standards, such as a wired LAN (local area network) or a wireless LAN, and can send and receive various data with the outside. For example, the pass / fail determination result performed by the determination unit 53f is output to the outside through the communication unit 534.

[0114] Next, the above-mentioned various functional sections constituting the image processing device 53 will be described in detail.

[0115] The main control unit 53a is a functional unit responsible for controlling the entire inspection device 21, and is configured to send and receive various signals to other functional units such as the lighting control unit 53b and the camera control unit 53c.

[0116] The lighting control unit 53b is a functional unit that controls the light sources 51a to 51c based on a command signal from the main control unit 53a.

[0117] The camera control unit 53 c is a functional unit that controls the camera 52 , and controls the timing of photographing by the camera 52 and the like based on a command signal from the main control unit 53 a .

[0118] The display control unit 53 d controls display contents on the display unit 532 based on the information stored in the storage unit 533 .

[0119] The image acquisition unit 53 e is a functional unit for acquiring luminance image data captured by the camera 52 .

[0120] The determination unit 53f is a functional unit that determines whether the container film 3 is acceptable based on the brightness image data obtained by the camera 52. The determination unit 53f includes a hole determination unit 53g, a foreign matter determination unit 53h, and a thickness determination unit 53j.

[0121] The hole determination unit 53g determines that the area whose brightness is higher than the brightness L1 as the brightness threshold value in the brightness image data obtained by the camera 52 is the hole HB. More specifically, the hole determination unit 53g determines the area occupied by the container film 3 from the brightness image data using the above-mentioned area determination information stored in the storage unit 533, and also determines the area whose brightness is higher than the brightness L1 in the area. On this basis, if the area (number of pixels) of the high brightness area is greater than or equal to a predetermined value, the hole determination unit 53g determines that the high brightness area is the hole HB. In addition, the brightness L1 is set to, for example, "2.9" which corresponds to the amount of light received by the camera 52.

[0122] The foreign matter determination unit 53h determines that the area whose brightness is lower than the brightness L4 as the brightness threshold value in the brightness image data is a foreign matter IB. More specifically, the foreign matter determination unit 53h determines the area occupied by the container film 3 from the brightness image data using the above-mentioned area determination information, and also determines the area whose brightness is lower than the brightness L4 in the area. On this basis, if the area (number of pixels) of the low brightness area is greater than or equal to a predetermined value, the foreign matter determination unit 53h determines that the low brightness area is a foreign matter IB. In addition, the brightness L4 is set to, for example, "0.1" which is equivalent to the amount of light received by the camera 52.

[0123] The thickness determination unit 53j determines whether the thickness of the container film 3 is acceptable based on the brightness of the area between brightness L4 and brightness L1 in the brightness image data. The thickness determination unit 53j includes a bag thickness determination unit 53k and a flange thickness determination unit 53m.

[0124] The bag thickness determination unit 53k determines whether the thickness of the bag 2 is acceptable or not based on the brightness of the area corresponding to the bag 2 in the brightness image data. More specifically, the bag thickness determination unit 53k determines the area occupied by the bag 2 (for example, the area occupied by the bottom of the bag 2) from the area with brightness L4 or higher and brightness L1 or lower in the brightness image data using the above-mentioned area determination information. On this basis, the bag thickness determination unit 53k calculates the area (number of pixels) of the area whose brightness is not within the preset first brightness range in the determined area. And, when the calculated area is greater than a predetermined value, the bag thickness determination unit 53k determines the thickness of the bag 2 as "unacceptable". On the other hand, when the calculated area is less than the predetermined value, the bag thickness determination unit 53k determines the thickness of the bag 2 as "acceptable". In addition, the so-called first brightness range is, for example, a range of brightness greater than "1.8" corresponding to the amount of light received by the camera 52 and less than "2.0" corresponding to the amount of light received.

[0125] The flange thickness determination unit 53m determines whether the thickness of the flange 3a is acceptable or not based on the brightness of the area corresponding to the flange 3a in the brightness image data. More specifically, the flange thickness determination unit 53m determines the area occupied by the flange 3a from the area with brightness L4 or higher and brightness L1 or lower in the brightness image data using the above-mentioned area determination information. On this basis, the flange thickness determination unit 53m calculates the area (number of pixels) of the area whose brightness is not within the preset second brightness range in the determined area. And, when the calculated area is greater than a predetermined value, the flange thickness determination unit 53m determines the thickness of the flange 3a as "unacceptable". On the other hand, when the calculated area is less than the predetermined value, the flange thickness determination unit 53m determines the thickness of the flange 3a as "acceptable". In addition, the so-called second brightness range is, for example, a range of brightness greater than "1.0" corresponding to the amount of light received by the camera 52 and less than "1.2" corresponding to the amount of light received.

[0126] As described in detail above, according to the present embodiment, the brightness difference between the hole HB and the thin-walled portion of the container film 3 can be set to be sufficiently large in the brightness image data. Thus, the hole determination unit 53g can determine the presence or absence of the hole HB in a manner sufficiently distinguishable from the thin-walled portion of the container film 3. In addition, the thickness determination unit 53j (the bag thickness determination unit 53k) can determine the pass / fail of the thickness in the thin-walled portion of the container film 3 in a manner sufficiently distinguishable from the hole HB. Thus, the presence or absence of the hole HB and the pass / fail of the thickness in the thin-walled portion of the container film 3 can be distinguished and detected more reliably.

[0127] Furthermore, according to the present embodiment, the brightness difference between the foreign matter IB and the thick wall portion of the container film 3 in the brightness image data can be set to be sufficiently large. Therefore, the foreign matter determination unit 53h can determine the presence or absence of the foreign matter IB in a manner sufficiently distinguishable from the thick wall portion of the container film 3. In addition, the thickness determination unit 53j (flange thickness determination unit 53m) can determine the pass / fail of the thickness of the thick wall portion of the container film 3 in a manner sufficiently distinguishable from the foreign matter IB. Thus, the presence or absence of the foreign matter IB and the pass / fail of the thickness in the thick wall portion of the container film 3 can be distinguished and detected more reliably.

[0128] Furthermore, since only one camera 52 is required, it is possible to reduce the size of the inspection device 21 and reduce the cost of manufacturing the inspection device 21.

[0129] Furthermore, the present invention is not limited to the contents of the above-mentioned embodiments, and can be implemented as follows, for example. Of course, other application examples and modification examples not shown below are also possible.

[0130] (a) In the above embodiment, the lighting device 51 includes the second light source 51c, and is configured so that the second light source 51c irradiates the container film 3 with light of wavelength λ2. Fig.10 As shown, the second light source 51 c may not be provided (omitted), and the container film 3 may be irradiated with the light beams of the wavelengths λ0 and λ1 simultaneously.

[0131] In this configuration, when a hole HB appears in the container film 3, the light beams of wavelengths λ0 and λ1 pass through the hole HB, so the total amount of light received by the camera 52 due to the hole HB becomes very large (see FIG. Fig.12 ). Therefore, the brightness of the hole portion HB in the brightness image data becomes very large.

[0132] On the other hand, in the thin-walled portion of the container film 3 having a thickness of approximately T2, such as the bottom of the bag portion 2, light of wavelength λ1 is not transmitted, and light of wavelength λ0 is transmitted only in an amount corresponding to the thickness of the portion (see Fig.11 ). Therefore, compared with the total amount of light received by the hole HB, the total amount of light received by the thin-walled portion (bag 2, etc.) of the camera 52 becomes very small (refer to Fig.12 ). As a result, the brightness of the thin-walled portion in the brightness image data becomes extremely small compared to the brightness of the hole HB.

[0133] Therefore, the hole determination unit 53g can determine the presence or absence of the hole HB in a manner sufficiently distinguishable from the thin-walled portion (e.g., the bottom of the pocket 2) in the container film 3. Moreover, the thickness determination unit 53j (pocket thickness determination unit 53k) can determine the quality of the container film 3 in a manner sufficiently distinguishable from the hole HB. Thus, the presence or absence of the hole HB and the quality of the container film 3 in a manner sufficiently distinguishable from the thickness can be more reliably distinguished and detected. In the above example, the inspection for foreign matter is omitted.

[0134] (b) In the above embodiment, the lighting device 51 is configured to irradiate the container film 3 with light of the wavelength λ0 by the first light source 51 a .

[0135] In contrast, Fig.13As shown, the lighting device 51 may have a low-wavelength first light source 51g and a high-wavelength first light source 51h, which are respectively equivalent to the first light source. In other words, the lighting device 51 may have two first light sources 51g and 51h as the first light source. Moreover, the structure is such that the low-wavelength first light source 51g irradiates the container film 3 with light (ultraviolet light) of a wavelength λ01, and the light of the wavelength λ01 corresponds to the thickness of the bag portion 2, and the transmittance of the light irradiated into the bag portion 2 varies, and the high-wavelength first light source 51f irradiates light (ultraviolet light) of a wavelength λ02, and the wavelength of the light of the wavelength λ02 is higher than λ01, and corresponds to the thickness of the flange portion 3a, and the transmittance of the light irradiated into the flange portion 3a varies. That is, the structure is such that the light of wavelengths λ01 and λ02 may be irradiated relative to the container film 3 as the light of wavelength λ0. Furthermore, in Fig.13 In the example shown, 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 is transmitted through the third half mirror 51j and emitted toward the container film 3.

[0136] In the above configuration, for the thin-walled portion of the container film 3 having a thickness of approximately T2, such as the bottom of the bag portion 2, light of wavelength λ01 is transmitted only in an amount corresponding to the thickness of the bag portion 2, while light of wavelength λ02 having a wavelength higher than wavelength λ01 is transmitted (see Fig.14 ). Therefore, the brightness of the thin-walled portion (bag portion 2, etc.) in the brightness image data becomes relatively large (refer to Fig.15 ).

[0137] On the other hand, in the thick wall portion of the container film 3 such as the flange portion 3a, light of wavelength λ02 is transmitted only in an amount corresponding to the thickness of the flange portion 3a, but light of wavelength λ01 lower than wavelength λ02 is difficult to transmit (see Fig.14 ). Therefore, the brightness of the flange portion 3a in the brightness image data becomes relatively small (refer to Fig.15 ).

[0138] Therefore, in the brightness image data, the difference between the brightness of the bag portion 2 and the brightness of the flange portion 3a can be set to be relatively large. As a result, the bag portion thickness determination unit 53k can determine the pass / fail of the thickness of the bag portion 2 with higher accuracy in a manner sufficiently distinguishable from the flange portion 3a. In addition, the flange portion thickness determination unit 53m can determine the pass / fail of the thickness of the flange portion 3a with higher accuracy in a manner sufficiently distinguishable from the bag portion 2. As a result, the accuracy of the pass / fail determination of the thickness of the bag portion 2 and the flange portion 3a can be further improved.

[0139] (c) In the above embodiment, the lighting device 51 is configured to irradiate lights of wavelengths λ0, λ1, and λ2 from a plurality of light sources 51a, 51b, and 51c. In contrast, as the lighting device, a device including a light source (e.g., a lamp light source) that can irradiate lights of a plurality of wavelengths at once and a bandpass filter for adjusting the wavelength of light irradiated from the light source to the container film 3 may be used. In this case, the container film 3 may be irradiated with lights of wavelengths λ0, λ1, and λ2 (or wavelengths λ0 and λ1) at once through the bandpass filter (i.e., lights of a plurality of wavelengths), or may be irradiated with lights of only wavelengths λ0, λ1, and λ2 (or wavelengths λ0 and λ1) at once. Furthermore, as the lighting device, the container film 3 may be irradiated with white light containing lights of wavelengths λ0, λ1, and λ2 (or wavelengths λ0 and λ1).

[0140] Of course, the configuration of the camera (such as sensitivity, etc.) may be appropriately changed in accordance with the lighting device.

[0141] (d) In the above embodiment, the tablet 5 is exemplified as the "content", but the content is not limited to the tablet.

[0142] Furthermore, the types and shapes of tablets are not limited to the above-mentioned embodiments. For example, tablets include not only pharmaceutical tablets but also dietary tablets. Furthermore, tablets include uncoated tablets, sugar-coated tablets, film-coated tablets, enteric-coated tablets, gelatin-coated tablets, etc., and also include various capsule tablets such as hard capsules and soft capsules.

[0143] The shape of the tablet may not only be a circular shape in plan view, but may also be, for example, a polygonal shape in plan view, an elliptical shape in plan view, an oblong shape in plan view, or the like.

[0144] (e) The structure of the manufactured PTP sheet is not limited to the above-mentioned embodiment. For example, the arrangement and number of the pockets 2 per unit of the PTP sheet 1 are not limited at all to the above-mentioned embodiment.

[0145] In the above embodiment, the PTP film 6 is constructed such that the number of bags 2 corresponding to one sheet is arranged along its width direction, but it is not limited to this. For example, it can be constructed such that the number of bags 2 corresponding to multiple sheets is arranged along its width direction.

[0146] (f) In the above embodiment, the inspection device 21 is applied to the PTP packaging machine 10, but the inspection device 21 can also be applied to a blister packaging machine that produces blister sheets other than the PTP sheet 1.

[0147] [Explanation of symbols]

[0148] 1…PTP sheet (blister sheet), 2…bag portion, 3…container film, 3a…flange portion, 4…cover film, 5…tablet (content), 10…PTP packaging machine (blister packaging machine), 21…inspection device, 51…illumination device (irradiation mechanism), 52…camera (video recording mechanism), 53…image processing device (determination mechanism), 53g…hole portion determination portion (hole portion determination mechanism), 53h…foreign matter determination portion (foreign matter determination mechanism), 53j…thickness determination portion (thickness determination mechanism), 53k…bag portion thickness determination portion (bag portion thickness determination mechanism), 53m…flange portion thickness determination portion (flange portion thickness determination mechanism), IB…foreign matter, HB…hole portion.

Claims

1. An inspection device for inspecting a resin container film having a bag portion for storing contents, characterized in that: The inspection device has: an irradiation mechanism for irradiating predetermined light to the container film; an imaging mechanism disposed on the opposite side of the container film from the irradiation mechanism via the container film, capable of capturing light irradiated by the irradiation mechanism and transmitted through the container film to obtain brightness image data; and A determination mechanism, which determines whether the container film is qualified or not according to the brightness image data obtained by the camera mechanism; The irradiation mechanism is configured to irradiate the container film with light of wavelength λ0 and light of wavelength λ1 simultaneously. The light of wavelength λ0 varies in transmittance of the light irradiated to the imaging mechanism side in accordance with the thickness of the container film. The light of wavelength λ1 has a wavelength lower than wavelength λ0 and cannot pass through the container film. The camera is configured to capture at least light of wavelength λ0 and light of wavelength λ1. The determination mechanism comprises: a hole determination unit that determines, in the brightness image data obtained by the imaging unit, a region with a brightness higher than a predetermined brightness L1 as a hole; and A thickness determination means determines whether the thickness of the container film is acceptable or not based on the brightness of the area in the area having a brightness L1 or less in the brightness image data.

2. The inspection device according to claim 1, characterized in that: The irradiation mechanism is configured to irradiate the container film with light of wavelength λ0 and light of wavelength λ1 and simultaneously with light of wavelength λ2, wherein the wavelength of the light of wavelength λ2 is higher than the wavelength λ0 and completely passes through the container film. The camera is configured to capture at least light of wavelength λ0, light of wavelength λ1, and light of wavelength λ2. The determination means includes a foreign matter determination means, which determines that a region in the brightness image data with a brightness lower than a predetermined brightness L4 is a foreign matter, The thickness determination unit is configured to determine whether the thickness of the container film is acceptable or not based on the brightness of the region in the region having a brightness of L4 or more and a brightness of L1 or less in the brightness image data.

3. The inspection device according to claim 1, characterized in that: The container film has a flat flange portion located at the periphery of the opening of the bag portion, and the flange portion is thicker than the wall of the bag portion. The irradiation mechanism is configured to irradiate light of wavelength λ01 and light of wavelength λ02 as light of wavelength λ0, wherein the light of wavelength λ01 causes a change in transmittance of the light irradiated to the camera mechanism side in the bag portion in accordance with the thickness of the bag portion, and the light of wavelength λ02 has a wavelength higher than wavelength λ01, causes a change in transmittance of the light irradiated to the camera mechanism side in the flange portion in accordance with the thickness of the flange portion, The thickness determination mechanism comprises: a bag thickness determination mechanism for determining whether the bag thickness is acceptable or not based on the brightness of an area corresponding to the bag in the brightness image data; and A flange thickness determination unit is provided for determining whether the flange thickness is acceptable or not based on the brightness of a region corresponding to the flange in the brightness image data.

4. A blister packaging machine for producing blister sheets, the blister packaging machine having the inspection device according to claim 1, wherein the blister sheet is configured such that a blister film is covered relative to the container film in a manner to seal the bag portion while the contents are contained in the bag portion formed by the container film.

Images