Inspection apparatus, inspection method, and program

Abstract

To provide a technique capable of accurately measuring the shape of an inspection object and detecting an inspection object having an inappropriate shape.SOLUTION: An inspection apparatus for inspecting an inspection object includes: a light source for irradiating an inspection object with light; an imaging unit for imaging the inspection object and generating an image of the inspection object by performing gain adjustment so that a whiteout region or a black crushing region is formed in at least a part of a predetermined region of the imaged inspection object; a determination unit for determining whether or not the shape of the inspection object satisfies a predetermined criterion on the basis of the image of the inspection object; and a control unit for controlling the light quantity of the light with which the inspection object is irradiated from the light source on the basis of setting or an instruction of a user so that a whiteout region or a black crushing region is formed in at least a part of the predetermined region of the image of the inspection object.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to an inspection device, an inspection method, and a program. [Background technology]

[0002] 2. Description of the Related Art As an absorbent article for absorbing liquids such as urine and body fluids, a tape-type absorbent article is known (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-97871 A Summary of the Invention [Problem to be solved by the invention]

[0004] A tape-type absorbent article is shipped after a tape (tab) is attached to the absorbent article and packaged in a folded state, and is unfolded when worn. Since the tape is attached to the absorbent article in a folded state, it is required to detect whether the tape is properly folded. For example, whether the tape is properly folded is detected by inspecting whether the shape of the tape after being folded is proper. However, when a pattern or the like is added to the tape, there is a problem that the edge of the tape is erroneously detected and the shape of the tape cannot be accurately detected.

[0005] Therefore, an object of the present invention is to provide a technique capable of accurately measuring the shape of an object to be inspected and detecting an object to be inspected that has an inappropriate shape. [Means for solving the problem]

[0006] An inspection device according to one aspect of the present invention is an inspection device for inspecting an object to be inspected, and includes a light source that irradiates light onto the object to be inspected, an imaging unit that images the object to be inspected and generates an image of the object to be inspected by adjusting gain so that a blown-out white area or a crushed black area is formed in at least a portion of a specified area of ​​the imaged object to be inspected, a control unit that controls the amount of light irradiated from the light source to the object to be inspected based on predetermined settings or user instructions so that the blown-out white area or the crushed black area is formed in at least a portion of the specified area in the image of the object to be inspected, and a judgment unit that judges whether the shape of the object to be inspected satisfies a predetermined standard based on the image of the object to be inspected. Effect of the Invention

[0007] According to the present invention, the shape of an object to be inspected can be accurately measured, and an object to be inspected having an improper shape can be detected. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of a diaper according to an embodiment. [Diagram 2] FIG. 2 is an exploded perspective view of the diaper according to the embodiment. [Diagram 3] FIG. 3 is a cross-sectional view of the diaper according to the embodiment in an unworn state, cut widthwise at the center in the longitudinal direction. [Figure 4] FIG. 4 is a plan view of the diaper according to the embodiment in a stretched state, as viewed from the skin-facing side. [Diagram 5] FIG. 5 is a plan view of the diaper according to the embodiment with the side flap portions folded. [Figure 6] FIG. 6 is a plan view of a sheet member for forming a tape of a diaper according to an embodiment. [Figure 7] FIG. 7 is a schematic configuration diagram of an inspection device according to an embodiment. [Figure 8] FIG. 8 is a diagram showing an example of a sheet member in a state where the tape is folded. [Figure 9]FIG. 9 is a schematic diagram of the camera according to the embodiment. [Figure 10] FIG. 10 is a flow chart showing an example of a process for inspecting a sheet member that is an object to be inspected. [Figure 11] Fig. 11A is a diagram showing an example of a sheet member, and Fig. 11B is a diagram showing an example of an image of the sheet member when an image of a region indicated by a dashed dotted line in Fig. 11A is captured. [Figure 12] Fig. 12A is a diagram showing an example of a sheet member, and Fig. 12B is a diagram showing an example of an image of the sheet member when an image of a region indicated by a dashed dotted line in Fig. 12A is captured. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An inspection device according to an embodiment of the present invention will be described below with reference to the drawings. The inspection device is capable of detecting folding defects of a tape (tab) in the manufacturing process of a tape-type disposable diaper. Note that the configurations of the following embodiments are merely examples, and the present invention is not limited to the configurations of these embodiments.

[0010] <Embodiment> In this embodiment, the longitudinal direction of a tape-type disposable diaper (an example of an "absorbent article" in the present application, hereinafter simply referred to as a "diaper") is the direction connecting the front body arranged opposite the wearer's abdomen and the rear body arranged opposite the wearer's back. Between the front body (one side in the longitudinal direction) and the rear body (the other side in the longitudinal direction) (the center in the longitudinal direction), a crotch portion arranged under the wearer's crotch (opposed to the crotch). In addition, when the diaper is worn by a wearer (hereinafter abbreviated as "worn state"), the side facing the wearer's skin (the inner side when worn) is the skin-facing side, and the opposite side of the skin-facing side (the outer side when worn) is the non-skin-facing side. Furthermore, the direction connecting the skin-facing side and the non-skin-facing side is the thickness direction, and the direction perpendicular to both the longitudinal direction and the thickness direction is the width direction. In addition, the view from the thickness direction is the planar view.

[0011] FIG. 1 is a perspective view of a diaper according to the present embodiment. The diaper 1 has a crotch region 1B, which is a region corresponding to the crotch of the wearer covering the pubic area when worn, a front body region 1F, which is located in front of the crotch region 1B and corresponds to the front body of the wearer, and a back body region 1R, which is located behind the crotch region 1B and corresponds to the back body of the wearer. Tapes 2L and 2R that can be attached to a front patch 2F provided on the non-wearer side surface of the front body region 1F are provided on both left and right edges of the back body region 1R. When the tapes 2L and 2R are attached to the front patch 2F with the front body region 1F positioned on the wearer's abdomen and the back body region 1R positioned on the wearer's back, the diaper 1 is fixed to the wearer's body in a state surrounding the wearer's waist circumference and thighs. Since the diaper 1 is fixed to the wearer's body in this manner, the wearer can stand and walk while wearing the diaper 1.

[0012] In the diaper 1, an absorbent capable of absorbing and retaining liquid is mainly disposed near the crotch region 1B. In addition, in order to prevent the formation of a gap between the diaper 1 and the wearer's skin that can be a liquid outflow path, the diaper 1 is provided with leg gathers 3AL, 3AR at a portion surrounding the wearer's legs (thighs), and three-dimensional gathers 3BL, 3BR are provided on the inner side of the leg gathers 3AL, 3AR in the width direction of the diaper 1, and a waist gather 3R is provided at a portion surrounding the wearer's abdominal circumference. The leg gathers 3AL, 3AR, the three-dimensional gathers 3BL, 3BR, and the waist gathers 3R are in close contact with the wearer's skin by the elastic force of the elastic members. Therefore, liquid discharged from the wearer's private parts is absorbed by the absorbent of the diaper 1 without leaking out of the diaper 1. As the elastic member, a thread-like or strip-like rubber or the like can be appropriately selected.

[0013] FIG. 2 is an exploded perspective view of the diaper 1. FIG. 3 is a cross-sectional view of the diaper 1 when not worn, cut in the width direction at the center in the longitudinal direction. FIG. 4 is a plan view of the diaper 1 when stretched, as viewed from the skin-facing side. In FIG. 4 and subsequent figures, the dashed line C1 is a center line representing the center of the diaper 1 in the width direction. The diaper 1 has a cover sheet 4 that forms an outer surface when worn. The cover sheet 4 is a sheet-like member having a substantially rectangular appearance with constrictions 4KL, 4KR at the portions corresponding to the long sides, and forms the exterior surface of the diaper 1. The constrictions 4KL, 4KR are provided at the portions where the wearer's thighs are located (leg surrounding regions 10L, 10R shown in FIG. 4). The cover sheet 4 is provided to reinforce the back sheet 5 described later and to improve the feel, and for example, a nonwoven fabric made of a liquid-impermeable thermoplastic resin can be used as the material for the cover sheet 4 in order to suppress leakage of excrement. Examples of liquid-impermeable thermoplastic resins include polyethylene (PE), polypropylene (PP), etc. The cover sheet 4 is not limited to a single-layer structure, and may be a multi-layer structure having an inner cover sheet and an outer cover sheet.

[0014] The diaper 1 has a back sheet 5, an absorbent 6C, and a top sheet 7, which are laminated in this order on the wearer's side of the cover sheet 4. The back sheet 5, the absorbent 6C, and the top sheet 7 are all sheet-like members having a substantially rectangular appearance, and are laminated in this order on the cover sheet 4 with their longitudinal directions coinciding with the longitudinal direction of the cover sheet 4. The back sheet 5, like the cover sheet 4, is a sheet formed of a liquid-impermeable thermoplastic resin material to suppress leakage of excrement. The back sheet 5 is preferably made of a material that also has moisture permeability to suppress stuffiness when worn. The top sheet 7 is a sheet-like member that is disposed on the skin side of the wearer so as to cover the water-absorbing surface of the absorbent 6C. The top sheet 7 is liquid permeable in part or in its entirety. Therefore, when the diaper 1 is worn, liquid excreted from the wearer passes through the top sheet 7, which may come into contact with the wearer's skin, and enters the absorbent 6C, where it is absorbed. For example, a woven fabric, a nonwoven fabric, or a porous film can be used as the material for the top sheet 7. The top sheet 7 may be hydrophilic. The absorbent body 6C is disposed so as to include the crotch region 1B.

[0015] The back sheet 5, the absorbent 6C, and the top sheet 7 all extend from the front body region 1F to the rear body region 1R. Therefore, when the wearer's private parts are covered with the cover sheet 4 in which the back sheet 5, the absorbent 6C, and the top sheet 7 are laminated, the longitudinal ends of the back sheet 5, the absorbent 6C, and the top sheet 7 are located on the wearer's ventral side and back side. In other words, the wearer's private parts are covered by the absorbent 6C from the wearer's ventral side to the back side. Therefore, whether the wearer is in a ventral or back-facing position when excreting liquid, the excreted liquid comes into contact with the absorbent 6C via the top sheet 7.

[0016] The diaper 1 has elastic members 4SL, 4SR for forming the leg gathers 3AL, 3AR between the cover sheet 4 and the back sheet 5 so as to stretch in the longitudinal direction of the diaper 1. The elastic members 4SL, 4SR are provided in an appropriate number (three in this embodiment) determined according to the elastic force (contractile force) required in the design of the diaper 1. As shown in FIG. 4, the leg gathers 3AL, 3AR are arranged at both widthwise end portions of the crotch region 1B, including the leg surrounding regions 10L, 10R, which are the regions where the wearer's thighs are located in the diaper 1. The leg surrounding regions 10L, 10R are arranged at both widthwise end portions of the crotch region 1B. The elastic members 4SL, 4SR are arranged in the leg gathers 3AL, 3AR.

[0017] The diaper 1 also has long, narrow, strip-like side sheets 8L, 8R. The side sheets 8L, 8R are liquid-impermeable sheets provided on the long sides of the top sheet 7. Like the cover sheet 4, the side sheets 8L, 8R have a plurality of layers of polyurethane foam at the regions where the wearer's thighs are located (see FIG. 4). The side sheets 8L, 8R are provided with constrictions 8KL, 8KR in the leg surrounding regions 10L, 10R shown in FIG. 1. Elastic members 8EL, 8ER for forming the three-dimensional gathers 3BL, 3BR are arranged in the longitudinal direction of the side sheets 8L, 8R. When the diaper 1 is worn, i.e., when the diaper 1 is U-shaped in side view, the side sheets 8L, 8R are pulled in the longitudinal direction by the contractile force of the elastic members 8EL, 8ER and rise from the top sheet 7, forming the three-dimensional gathers 3BL, 3BR that prevent liquid from leaking out.

[0018] The cover sheet 4 is provided with elastic members 4C, which prevent a gap from being formed between the diaper 1 and the wearer's abdominal circumference, on the inner side in the width direction of the diaper 1 than the elastic members 4SL, 4SR and along the longitudinal direction of the diaper 1. The elastic members 4C are provided according to the elastic force (contractile force) required for the design of the diaper 1.

[0019] Furthermore, the elastic member 9ER for forming the above-mentioned waist gathers 3R is provided between the back sheet 5 and the top sheet 7, at a position further back than the end of the absorbent body 6C. The elastic member 9ER is provided between the back sheet 5 and the top sheet 7 with its longitudinal direction, which is the stretch direction, oriented in the left-right direction of the diaper 1. Thus, when the tapes 2L, 2R provided on both the left and right sides of the elastic member 9ER are attached to the front patch 2F on the abdominal side of the wearer, the elastic member 9ER exerts a contractile force to bring the diaper 1 into close contact with the wearer and prevent the formation of a gap between the diaper 1 and the wearer's abdominal circumference.

[0020] The absorbent 6C has a structure in which granular absorbent resin such as SAP (Super Absorbent Polymer), which is a hydrophilic polymer with a cross-linked structure capable of absorbing and retaining water, is held in the gaps between short fibers of cellulosic fibers such as pulp fibers, rayon fibers, or cotton fibers, or short fibers obtained by hydrophilizing synthetic fibers such as polyethylene, polypropylene, or polyethylene terephthalate. Therefore, in the absorbent 6C, the volumetric change of the absorbent resin before and after absorbing liquid basically occurs within the short fibers that hold the absorbent resin in the gaps. Therefore, when the absorbent 6C is viewed as a whole, it can be said that the expansion rate of the thickness of the absorbent 6C that has absorbed liquid is not as large as the expansion rate of the absorbent resin itself.

[0021] The SAP particles of this embodiment refer to a resin composition containing SAP in a granular form. The term "SAP-containing resin composition" as used herein includes both a composition consisting of SAP alone and a composition containing SAP as the main component and containing other substances to the extent that they do not adversely affect the water absorption. Examples of "other substances" include additives (such as surface modifiers added to make the particle surface hydrophobic) and unreacted monomers remaining during the synthesis of SAP.

[0022] Next, the tapes 2L, 2R of the diaper 1 according to this embodiment will be described with reference to Fig. 4. As shown in Fig. 4, the diaper 1 according to this embodiment is provided with a pair of side flap portions 11L, 11R arranged in the rear body region 1R and extending outward in the width direction of the diaper 1 beyond the absorbent body 6C. In this embodiment, the side flap portions 11L, 11R are configured to include a cover sheet 4 forming the exterior surface of the diaper 1, and side sheets 8L, 8R joined to the skin-facing side of the cover sheet 4 for forming three-dimensional gathers 3BL, 3BR. The diaper 1 also includes tapes 2L, 2R connected to the pair of side flap portions 11L, 11R, respectively, and attached to a front patch 2F arranged in the front body region 1F for fixing the diaper 1 to the waist of a wearer.

[0023] The tapes 2L, 2R have base ends 20L, 20R fixed to the side flap portions 11L, 11R, and tape base portions 21L, 21R extending outward in the width direction from the side flap portions 11L, 11R. The base ends 20L, 20R and the tape base portions 21L, 21R are made of nonwoven fabric. The tape base 21L, 21R is formed of a single sheet member such as the tape base 21L, 21R. The base end 20L, 20R is disposed between the cover sheet 4 and the side sheet 8L, 8R constituting the side flap portion 11L, 11R, and is bonded to at least one of the cover sheet 4 and the side sheet 8L, 8R with an adhesive. This connects the tape 2L, 2R to the side flap portion 11L, 11R. Also, the hook portion 22L, 22R is disposed on the skin-facing side of the tape base 21L, 21R. The hook portion 22L, 22R is engageable with the front patch 2F. The front patch 2F has a loop portion on its surface that is engageable with the hook portion 22L, 22R. The hook portion 22L, 22R engages with the loop portion of the front patch 2F, whereby the tape 2L, 2R is attached to the front body region 1F of the diaper 1. Alternatively, the front patch 2F may not be disposed in the front body region 1F, and the hook portions 22L, 22R may be capable of engaging with the cover sheet 4 in the front body region 1F.

[0024] The diaper 1 is shipped with the tape bases 21L, 21R of the tapes 2L, 2R folded toward the skin along the fold lines FL1, FR1, and the side flaps 11L, 11R folded toward the skin along the fold lines FL2, FR2 (shown by two-dot chain lines in Figs. 4 and 5). The fold lines FL2, FR2 extend in the longitudinal direction of the diaper 1, and the side flaps 11L, 11R are folded toward the skin along the fold lines FL2, FR2. When the absorbent body 6C is hourglass-shaped as in this embodiment, the fold lines FL2, FR2 are defined on the widthwise ends of the absorbent body 6C in the crotch region 1B.

[0025] Fig. 5 is a plan view of the diaper 1 viewed from the skin side with the side flap portions 11L, 11R folded along the fold lines FL2, FR2. As shown in Fig. 5, the side flap portions 11L, 11R are folded toward the skin side of the diaper 1. As shown in Fig. 5, the tapes 2L, 2R are folded toward the skin side of the diaper 1.

[0026] FIG. 6 is a plan view of the sheet member S for forming the tapes 2L and 2R. The tapes 2L and 2R are formed by cutting the sheet member S into the shape of a tape. The dotted lines in FIG. 6 are cutting lines of the sheet member S, and a plurality of tapes 2L and 2R can be formed from one sheet member by cutting the sheet member S along these dotted lines. A cutting device equipped with a cutter roll and anvil roll can be used to cut the sheet member S. FIG. 6 shows the sheet member S viewed from the skin-facing side with the tapes 2L and 2R connected to the side flap portions 11L and 11R. The tapes 2L and 2R are formed alternately along the longitudinal direction of the sheet member S.

[0027] 6, a hook sheet 30 is joined to the center in the width direction of the sheet member S. The hook sheet 30 becomes the hook portions 22L, 22R in the tapes 2L, 2R obtained by cutting the sheet member S.

[0028] In the process of preparing the tapes 2L, 2R by cutting the sheet member S along the dotted lines, the base ends 20L, 20R and the tape bases 21L, 21R on which the hook portions 22L, 22R are arranged can be formed. After cutting the tapes 2L, 2R, the fold lines FL1, FR1 are formed. The fold lines FL1, FR1 extend in the longitudinal direction of the diaper 1 between the hook portions 22L, 22R and the base ends 20L, 20R. The tape bases 21L, 21R are folded along the fold lines FL1, FR1.

[0029] In the manufacturing process of the diaper 1, a cut is made along a part of the cutting line of the sheet member S, the tapes 2L, 2R are folded, and then the sheet member S is cut into the shape of a tape to form the tapes 2L, 2R. The folded tapes 2L, 2R are then attached to the side flap portions 11L, 11R. If the tapes 2L, 2R are not properly folded, it may not be possible to properly cut the tapes 2L, 2R from the sheet member S. If a folding defect occurs in 2R, the tapes 2L, 2R may not be properly attached to the side flap portions 11L, 11R. Therefore, the sheet member S having the tapes 2L, 2R is inspected to detect any folding defect in the tapes 2L, 2R.

[0030] The inspection of the sheet member S having tapes 2L and 2R will be described. FIG. 7 is a schematic diagram of an inspection device 100 according to an embodiment. The inspection device 100 is a device that inspects the sheet member S, which is an object to be inspected, and is configured to be able to detect defects in the sheet member S. After a cut is made along a part of the cutting line of the sheet member S and the tapes 2L and 2R are folded, the inspection device 100 inspects the sheet member S. FIG. 8 is a diagram showing an example of the sheet member S in a state in which a cut is made along a part of the sheet member S and the tapes 2L and 2R are folded.

[0031] The inspection device 100 includes a controller 110, a camera 120, a light source 130, and a display device 140. As shown in FIG. 7, the camera 120 is disposed near the sheet member S. The sheet member S may be conveyed using a conveying device 150, and the camera 120 may capture an image of the sheet member S being conveyed. The conveying device 150 is, for example, a conveying roller that conveys the sheet member S in a predetermined direction. The sheet member S is a long, strip-shaped sheet member, and is conveyed with its longitudinal direction as the conveying direction. The sheet member S is conveyed in a state in which a certain tension is applied along the conveying direction. The camera 120 and the light source 130 may be disposed on the front side (front surface side) of the sheet member S, or may be disposed on the rear side (rear surface side) of the sheet member S. A black sheet may be provided on the side where the camera 120 and the light source 130 are disposed. The camera 120 and the light source 130 may be disposed opposite each other with the sheet member S interposed therebetween. The camera 120 may be disposed on the front side (surface side) of the sheet member S, and the light source 130 may be disposed on the rear side (rear side) of the sheet member S. The camera 120 may be disposed on the rear side (rear side) of the sheet member S, and the light source 130 may be disposed on the front side (surface side) of the sheet member S.

[0032] The controller 110 is a control device that controls the camera 120, the light source 130, and the display device 140. The controller 110 is, for example, a central processing unit (CPU) or the like. The controller 110 may be configured by a computer having a processor, a RAM (Random Access Memory), a non-volatile storage device, etc. Examples of the non-volatile storage device include a ROM (Read Only Memory) and a flash memory. The controller 110 may be an Industrial Computer (IC), an Industrial Personal Computer (IPC), or a Programmable Logic Controller (PLC). All or a part of the functions provided by the controller 110 may be configured with a circuit such as an Application Specific Integrated Circuit (ASIC) or a Field Programmable Gate Array (FPGA). The controller 110 has a control unit that controls the amount of light irradiated from the light source 130, and a determination unit that determines whether or not the shape of the sheet member S, which is the object to be inspected, satisfies a predetermined standard.

[0033] The camera 120 is an imaging device (imaging section) that images the sheet material S. FIG. 9 is a schematic diagram of the camera 120 according to the embodiment. The camera 120 includes a lens section 121, an imaging element section 122, a processing section 123, and an input / output I / F 124. The lens section 121 is an optical system that forms an optical image of the sheet material S on the imaging element section 122, and an optical system having functions such as autofocus (AF), aperture, and zoom is used. The imaging element section 122 is a device that generates and outputs an image signal by photoelectric conversion, and is configured with an imaging element such as a CCD (Charge Coupled Device) or a CMOS (Complementary Metal Oxide Semiconductor). The processing section 123 generates an image (image data) of the sheet material S based on the image signal output from the imaging element section 122. The processing section 123 is configured with, for example, a processor and a memory, and executes various processes by the processor reading and executing a program stored in the memory. The processing unit 123 may be a DSP (Digital Signal Processor). The input / output I / F 124 is a communication interface that transmits and receives data to and from the controller 110.

[0034] The light source 130 is an illumination device that illuminates an imaging range of the sheet member S imaged by the camera 120, and irradiates the sheet member S with light. The light source 130 emits, for example, white light. Examples of the light source 130 include an LED (Light Emitting Diode), an OLED (Organic Light Emitting Diode), a fluorescent lamp, and an incandescent lamp. FIG. 9 shows an example in which the controller 110 controls the light source 130, but is not limited to the example shown in FIG. For example, a light source power supply device may control the light source 130. The display device 140 is a device that displays various data and information. The display device 140 displays various data and information processed by the controller 110. The display device 140 is, for example, a liquid crystal display, an organic EL (Electro Luminescence) display, or the like. The display device 140 may include an input device such as an operation button and a touch panel. The touch panel may be configured as an integral part of the display device 140. Information input to the input device of the display device 140 is sent to the controller 110.

[0035] In the example shown in FIG. 7, the camera 120 is arranged so that the lens unit 121 of the camera 120 faces the horizontal direction, and the camera 120 captures an image of the sheet material S arranged in the horizontal direction, but is not limited to the example shown in FIG. The camera 120 may be arranged so that the lens unit 121 of the camera 120 faces upward. In this case, the sheet material S is transported above the camera 120, and the light source 130 is arranged above the sheet material S. The camera 120 may also be arranged so that the lens unit 121 of the camera 120 faces downward. In this case, the sheet material S is transported below the camera 120, and the light source 130 is arranged below the sheet material S.

[0036] FIG. 10 is a flowchart showing an example of a process for inspecting a sheet member S, which is an object to be inspected. For example, after conveyance of the sheet member S is started, the process of the flowchart in FIG. 10 is executed. At least one of a pattern, a character, and a figure is added to the sheet member S. For example, at least one of a pattern, a character, and a figure is added to one side, the other side, or both sides of the sheet member S. The pattern, the character, and the figure on the sheet member S are applied by printing or embossing. Hereinafter, at least one of a pattern, a character, and a figure will be referred to as a pattern, etc.

[0037] In step S301, the controller 110 adjusts the amount of light irradiated from the light source 130 to the sheet member S. For example, the controller 110 controls the light source 130 so that the amount of light irradiated from the light source 130 to the sheet member S falls outside a predetermined range. The controller 110 may control the light source 130 so that the amount of light irradiated from the light source 130 to the sheet member S exceeds a first threshold. The controller 110 may control the light source 130 so that the amount of light irradiated from the light source 130 to the sheet member S falls below a second threshold. The first threshold may be a maximum value (upper limit value) in a predetermined range. The second threshold may be a minimum value (lower limit value) in a predetermined range. The first threshold and the second threshold are obtained in advance by an experiment or a simulation, and are stored in a storage unit of the controller 110. In addition, when a pattern or the like is not added to the sheet member S, the controller 110 controls the light source 130 so that the amount of light irradiated from the light source 130 to the sheet member S falls within a predetermined range.

[0038] In step S302, the camera 120 captures an image of the sheet material S to generate an image of the sheet material S. In detail, an image signal is output from the imaging element unit 122, and the processing unit 123 performs gain adjustment by adjusting the gain of the image signal. In this case, the processing unit 123 performs gain adjustment so that a blown-out white area or a crushed black area is formed in at least a part of a predetermined area of ​​the captured sheet material S to generate an image of the sheet material S. For example, when the brightness of the subject exceeds the upper limit of the dynamic range, blown-out white areas occur in the image. Therefore, the processing unit 123 performs gain adjustment so that the brightness of the sheet material S does not exceed the upper limit of the dynamic range. Thus, gain adjustment (high gain adjustment) is performed by increasing the gain of the image signal output from the image sensor unit 122. For example, when the brightness of the subject is below the lower limit of the dynamic range, black crush occurs in the image. Therefore, the processing unit 123 performs gain adjustment (low gain adjustment) by lowering the gain of the image signal output from the image sensor unit 122 so that the brightness of the sheet material S falls below the lower limit of the dynamic range. The predetermined area of ​​the sheet material S is, for example, an area other than the edge of the sheet material S.

[0039] The camera 120 captures an image of one side or the other side of the sheet material S to generate an image of the one side or the other side of the sheet material S. When one side of the sheet material S is captured, the processing unit 123 performs gain adjustment so that a whiteout region or a blackout region is formed in at least a portion of the image of the one side of the sheet material S to generate an image of the one side of the sheet material S. When the other side of the sheet material S is captured, the processing unit 123 performs gain adjustment so that a whiteout region or a blackout region is formed in at least a portion of the image of the other side of the sheet material S to generate an image of the other side of the sheet material S.

[0040] The controller 110 controls the amount of light irradiated from the light source 130 to the sheet member S so that a whiteout area or a blackout area is formed in at least a part of a predetermined area in the image of the captured sheet member S. The controller 110 controls the amount of light irradiated from the light source 130 to the sheet member S based on a predetermined setting or an instruction from a user. The controller 110 may control the amount of light irradiated from the light source 130 to the sheet member S based on a control value for controlling the amount of light irradiated from the light source 130 to the sheet member S. The control value may be predetermined or may be stored in a storage unit of the controller 110. A user may input the control value to the inspection device 100 via an operation unit of the inspection device 100, and the controller 110 may acquire the control value input to the inspection device 100. For example, the controller 110 controls the light source 130 so that the amount of light irradiated from the light source 130 to the sheet member S exceeds a first threshold, and adjusts the gain, thereby forming a whiteout area in at least a part of a predetermined area in the image of the captured sheet member S. For example, the controller 110 controls the light source 130 so that the amount of light irradiated from the light source 130 to the sheet material S falls below a second threshold, and performs gain adjustment, thereby forming a crushed black area in at least a portion of a specified area in the image of the captured sheet material S.

[0041] In step S303, the controller 110 detects the edge of the sheet material S based on the generated image of the sheet material S. For example, the controller 110 extracts a luminance value for each pixel in the image of the sheet material S, and detects a row of pixels in which the difference in luminance values ​​between two adjacent pixels is a predetermined value or more as the edge of the sheet material S.

[0042] For example, when a pattern or the like is added to a predetermined area of ​​the sheet member S, forming a blown-out highlight area or a crushed-black area in at least a part of the predetermined area of ​​the sheet member S makes it impossible to recognize a part or all of the pattern or the like in the predetermined area of ​​the sheet member S. That is, the controller 110 does not detect a part or all of the pattern or the like in the predetermined area of ​​the sheet member S as an edge of the sheet member S. Therefore, the controller 110 can accurately detect the edge of the sheet member S. When a black sheet is provided on the side where the camera 120 and the light source 130 are arranged, the edge of the sheet member S becomes clearer, and the controller 110 can more accurately detect the edge of the sheet member S.

[0043] In step S304, the controller 110 uses the edges of the sheet material S detected from the image of the sheet material S to determine whether or not the outer shape (outer edge) of the sheet material S satisfies a predetermined criterion.

[0044] 11A and 11B, a check is made to see whether the outer shape of the sheet member S satisfies a predetermined standard. An example of the determination process will be described. FIG. 11A is a diagram showing an example of a sheet member S. In the example shown in FIG. 11A, a part of the sheet member S is cut and the tapes 2L and 2R are folded. FIG. 11B is a diagram showing an example of an image of the sheet member S when an area 200 shown by a dashed line in FIG. 11A is imaged. For example, the camera 120 images the sheet member S being conveyed along the conveying direction shown in FIG. 11A, and generates an image of the sheet member S shown in FIG. 11B. In the state where a part of the sheet member S is cut and the tapes 2L and 2R of the sheet member S are folded, the sheet member S has unevenness in the planar direction of the sheet member S and in a direction perpendicular to the conveying direction of the sheet member S (vertical direction). A plurality of unevennesses are arranged on the sheet member S along the conveying direction of the sheet member S.

[0045] For example, the controller 110 extracts the unevenness of the sheet member S from the image of the sheet member S based on the edge 201 of the sheet member S detected from the image of the sheet member S shown in FIG. 11B. The controller 110 determines whether the shape (outer shape) of the sheet member S satisfies a predetermined standard based on whether the unevenness of the sheet member S has a predetermined shape. The controller 110 determines whether the height (D1) of the unevenness of the sheet member S falls within a predetermined range. The predetermined range can be set arbitrarily, and may be set to 18 mm or more and 22 mm or less, for example. When the height (D1) of the unevenness of the sheet member S is 20 mm, the controller 110 determines that the unevenness of the sheet member S has a predetermined shape and that the shape of the sheet member S satisfies the predetermined standard. If the height (D1) of the unevenness of the sheet member S is less than 18 mm, or if the height (D1) of the unevenness of the sheet member S exceeds 22 mm, the controller 110 determines that the unevenness of the sheet member S does not have a specified shape, and determines that the shape of the sheet member S does not satisfy a specified standard.

[0046] FIG. 12A is a diagram showing an example of a sheet member S. In the example shown in FIG. 12A, a part of the sheet member S is cut and the tapes 2L and 2R are folded. FIG. 12B is a diagram showing an example of an image of the sheet member S when an area 300 shown by a dashed line in FIG. 12A is imaged. For example, the camera 120 images the sheet member S being conveyed along the conveying direction shown in FIG. 12A, and generates an image of the sheet member S shown in FIG. 12B. In this state, a part of the sheet member S is cut and the tapes 2L and 2R of the sheet member S are folded, and the sheet member S has unevenness in the planar direction of the sheet member S and in a direction perpendicular to the conveying direction of the sheet member S (vertical direction). A plurality of unevennesses are arranged on the sheet member S along the conveying direction of the sheet member S.

[0047] For example, the controller 110 extracts the unevenness of the sheet member S from the image of the sheet member S based on the edge 301 of the sheet member S detected from the image of the sheet member S shown in FIG. 12B. The controller 110 determines whether the shape (outer shape) of the sheet member S meets a predetermined standard based on whether the unevenness of the sheet member S has a predetermined shape. The controller 110 determines whether the height (D2) of the unevenness of the sheet member S is within a predetermined range. The predetermined range can be set arbitrarily, and may be set to 18 mm or more and 22 mm or less, for example. As shown in FIG. 12A, a folding failure occurs in the tape 2R of the sheet member S. Therefore, the height (D2) of the unevenness of the sheet member S exceeds 22 mm, and the controller 110 determines that the unevenness of the sheet member S is not a predetermined shape, and determines that the shape of the sheet member S does not meet the predetermined standard.

[0048] The controller 110 may determine whether or not the shape of the sheet member S satisfies a predetermined standard by pattern matching that compares a sample image with the image of the sheet member S. The sample image is an image of the sheet member S that is captured when the shape of the sheet member S satisfies a predetermined standard. The controller 110 may compare the sample image with the image of the sheet member S to determine whether or not the unevenness of the sheet member S has a predetermined shape. If the unevenness of the sheet member S has the predetermined shape, the controller 110 determines whether or not the shape of the sheet member S satisfies the predetermined standard. If the concaves and convexes of the sheet member S do not have a predetermined shape, the controller 110 determines that the shape of the sheet member S does not satisfy a predetermined standard.

[0049] If the shape of the sheet member S satisfies the predetermined standard (step S304; YES), the process proceeds to step S305. In step S305, the controller 110 determines that the shape of the sheet member S is appropriate and that no defect has occurred in the shape of the sheet member S. That is, the controller 110 determines that the sheet member S is normal. If the shape of the sheet member S does not satisfy the predetermined standard (step S304; NO), the process proceeds to step S306. In step S306, the controller 110 determines that the shape of the sheet member S is not appropriate and that a defect has occurred in the sheet member S. This makes it possible to detect that the shape of the sheet member S is not appropriate and to detect a folding defect of the tapes 2L, 2R of the sheet member S.

[0050] According to the process of inspecting the sheet member S, the controller 110 detects the edge of the sheet member S based on the image generated by performing light amount adjustment and high gain adjustment. The controller 110 does not detect a part or all of the pattern in a predetermined area of ​​the sheet member S as the edge of the sheet member S, so that the edge of the sheet member S can be accurately detected. Therefore, the inspection device 100 can accurately measure the shape of the sheet member S and detect a sheet member S having an improper shape. When a folding defect occurs in the tapes 2L and 2R of the sheet member S, the shape of the sheet member S becomes improper. The inspection device 100 can detect a folding defect in the tapes 2L and 2R of the sheet member S by detecting a sheet member S having an improper shape.

[0051] <Other embodiments> The present invention may be understood as an inspection system or a manufacturing system having at least some of the configurations, means, and functions described above. The present invention may be understood as an inspection method or a manufacturing method including at least some of the processes described above. The present invention may be understood as a method in which a computer executes the processes described above. The present invention may be understood as a program for causing a computer to execute the processes described above, and the program may be provided to the computer via a network or from a computer-readable recording medium that non-temporarily holds data.

[0052] <Computer-readable recording medium> A program for making an information processing device or other machine or device (hereinafter, computer, etc.) realize any of the above functions can be recorded on a computer-readable recording medium. Then, the computer, etc. can provide the function by reading and executing the program from the recording medium. Here, a computer-readable recording medium refers to a recording medium that stores information such as data and programs by electrical, magnetic, optical, mechanical, or chemical action and can be read by a computer, etc. Among such recording media, those that can be removed from a computer, etc. include, for example, flexible disks, magneto-optical disks, CD-ROMs, CD-R / Ws, DVDs, Blu-ray disks, memory cards such as flash memories, etc. Furthermore, recording media fixed to a computer, etc. include hard disks, ROMs, etc. [Explanation of symbols]

[0053] 1. Diapers 2F: Front patch 2L, 2R Tape 4. Cover sheet 5. Back sheet 6C··Absorbent 7. Top sheet 8. Side seat FL1, FR1, FL2, FR2... fold lines S··Sheet material 100 Inspection equipment 110··Controller 120··Camera 121 Lens section 122 Imaging element section 123 Processing section 124 Input / Output Interface 130...Light source 140·Display device 150··Conveyor device 200,300·area 201,301 Edge

Claims

1. An inspection apparatus for inspecting an object to be inspected, A light source that irradiates light onto the object to be inspected; an imaging unit that images the object to be inspected and performs gain adjustment so that a whiteout region or a blackout region is formed in at least a part of a predetermined region of the imaged object to be inspected, thereby generating an image of the object to be inspected; a control unit that controls the amount of light irradiated from the light source to the object to be inspected based on a predetermined setting or an instruction from a user so that the whiteout region or the blackout region is formed in at least a part of the predetermined region in the image of the object to be inspected; a determination unit that determines whether or not a shape of the object to be inspected satisfies a predetermined standard based on the image of the object to be inspected; Equipped with Inspection equipment.

2. The test object is a sheet member having a tape for fixing the absorbent article to a wearer.

2. The inspection device according to claim 1.

3. At least one of a pattern, a character, and a graphic is added to the predetermined area of ​​the object to be inspected.

2. The inspection device according to claim 1.

4. The predetermined area of ​​the object to be inspected is an area other than an edge of the object to be inspected.

2. The inspection device according to claim 1.

5. The imaging unit images the inspection object being transported, the inspection object has projections and recesses in a planar direction of the inspection object and perpendicular to a transport direction of the inspection object, the determination unit determines whether or not the shape of the object to be inspected satisfies the predetermined criterion based on whether or not the unevenness in the image of the object to be inspected has a predetermined shape.

5. An inspection device according to claim 1.

6. An inspection method for an inspection device including a light source and an imaging unit, generating an image of the object to be inspected by performing gain adjustment so that a whiteout region or a blackout region is formed in at least a part of a predetermined region of the object to be inspected imaged by the imaging unit; controlling the amount of light irradiated from the light source to the object to be inspected based on a predetermined setting or a user instruction so that the whiteout region or the blackout region is formed in at least a part of the predetermined region in the image of the object to be inspected; determining whether or not a shape of the object to be inspected satisfies a predetermined criterion based on an image of the object to be inspected; Equipped with Testing method.

7. An inspection device including a light source and an imaging unit, generating an image of the object to be inspected by performing gain adjustment so that a whiteout region or a blackout region is formed in at least a part of a predetermined region of the object to be inspected imaged by the imaging unit; The predetermined region in the image of the object to be inspected is at least partially affected by the blown-out white area or the blown-out white area. controlling the amount of light irradiated from the light source to the object to be inspected based on a predetermined setting or a user's instruction so that the black crushed region is formed; determining whether or not a shape of the object to be inspected satisfies a predetermined criterion based on an image of the object to be inspected; A program for executing the above.

Images