Inspection device

Abstract

To provide an inspection device that can improve productivity or the like.SOLUTION: An inner surface including at least a seal area 2x of a tube container 2 is formed of a material causing no fluorescence by ultraviolet light, and a content S has vaseline. An inspection device 70 irradiates the inner surface of the tube container 2 with the ultraviolet light to capture an image of the ultraviolet light obtained by reflecting the content S through an axicon lens 72 after the tube container 2 is filled with the content S and before an opening of the tube container 2 is sealed. The device then determines quality of the seal area 2x relating to adhesion of the content S based on the image obtained by imaging. Since inspection is made in a stage before the sealing of the opening, which easily causes leakage of the content S, the need for cleaning for removing the leaked content S can be almost eliminated to enhance productivity. The seal area 2x and the content S can be also more clearly discriminated in the image to obtain excellent inspection capability.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to an inspection device for inspecting tube containers. [Background technology]

[0002] Tube containers are known as containers for storing semi-solid contents (e.g., toothpaste, cosmetics, food, etc.) One end of the tube container is provided with a seal portion formed by sealing the tube container in a flattened state.

[0003] However, if the contents are attached to the inner surface of one end of the tube container (the area to be sealed) when the seal is formed, the sealing condition at the seal will be inappropriate, which may result in problems with maintaining the quality of the contents, etc. Therefore, an inspection device for tube containers is sometimes used to inspect the sealing condition at the seal.

[0004] As such an inspection device, one that includes a pressing mechanism that presses the tube container, an imaging mechanism that images the tube container after pressing, and a judgment mechanism that judges the condition of the seal part based on the image obtained by the imaging mechanism has been proposed (see, for example, Patent Document 1, etc.). The judgment mechanism judges the quality of the seal part based on the presence or absence of leakage of the contents from the seal part.

[0005] Also known is an inspection device that includes an infrared heater that emits infrared light toward a tube container (object to be inspected), an infrared camera that captures the infrared light that has passed through the tube container, and an image processing device that judges the condition of the seal portion based on a perspective image obtained by the infrared camera (see, for example, Patent Document 2, etc.). The image processing device judges the quality of the seal portion by utilizing the difference in infrared light transmittance between a portion where contents are present and a portion where contents are not present. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2010-78453 A [Patent Document 2] JP 2006-64389 A Summary of the Invention [Problem to be solved by the invention]

[0007] However, the inspection device according to Patent Document 1 presses the tube container and judges whether the seal is good or bad based on whether the contents leak from the seal. If the seal is defective, the leaked contents may cause the device to become dirty. Therefore, cleaning is required to remove the leaked contents every time a seal defect occurs, making it difficult to increase productivity (production capacity). Furthermore, if the leaked contents are not removed, there is a risk of erroneous judgment due to the leaked contents.

[0008] In addition, in the inspection device according to Patent Document 2, the tube container is not pressed, but since leakage of the contents from the seal portion is likely to occur when the seal portion is formed, the device may be soiled by the leaked contents, as in the inspection device according to Patent Document 1. Therefore, the inspection device according to Patent Document 2 may also have the same problems as the inspection device according to Patent Document 1.

[0009] The present invention has been made in consideration of the above circumstances, and an object of the present invention is to provide an inspection apparatus that can improve productivity. [Means for solving the problem]

[0010] The following describes each of the means suitable for achieving the above object. Note that, as necessary, the specific effects of the corresponding means will be added.

[0011] Means 1. An inspection device used in manufacturing a tube product in which a plurality of tube containers are lined up and transported, and a filling process in which the tube containers are filled with contents through openings at the ends of the tube containers, and a sealing process in which the openings are sealed, the inspection device being capable of inspecting a seal area, which is an area of ​​the inner surface of the tube container that is to be sealed in the sealing process, comprising: At least an inner surface of the tube container including the sealing area is formed of a material that does not generate fluorescence when exposed to ultraviolet light, The content contains petrolatum, an irradiation means for irradiating an inner surface of the tube container including at least the sealing area with ultraviolet light after the filling step and before the sealing step; an image pickup element capable of picking up an image of the ultraviolet light irradiated from the irradiation means; an imaging lens that forms an image on the image sensor using ultraviolet light that is irradiated from the irradiating means and reflected by the contents; an axicon lens that is disposed vertically above the opening of the tube container between the tube container and the imaging lens, and is configured to convert an optical path of the ultraviolet light that is irradiated from the irradiation means and reflected off the contents into an optical path along an optical axis direction of the imaging lens; and a seal area quality determination means for determining the quality of the seal area with respect to adhesion of contents based on an image obtained by imaging with the imaging element.

[0012] According to the above-mentioned means 1, after the filling step and before the sealing step, the irradiation means irradiates ultraviolet light onto at least the inner surface of the tube container including the sealing area, and the imaging element obtains an image based on the ultraviolet light reflected from the contents. Then, the seal area quality determination means determines the quality of the seal area related to the adhesion of the contents based on the obtained image. Therefore, since the inspection is performed at a stage before the opening of the tube container is sealed to form a seal part, that is, before the formation of the seal part where the contents are likely to leak, it is possible to make it more difficult for the leaked contents to cause contamination of the device. As a result, cleaning to remove the leaked contents is almost unnecessary, and productivity (production capacity) can be improved.

[0013] According to the above-mentioned means 1, since the contents contain Vaseline, the ultraviolet light irradiated from the irradiation means can cause the contents to fluoresce. On the other hand, since the inner surface of the tube container is made of a material that does not fluoresce in response to ultraviolet light, it is possible to prevent the sealed area from fluorescing. This makes it possible to make the sealed area and the contents attached to the sealed area more clearly distinguishable in the image obtained by the imaging element. As a result, the contents attached to the sealed area can be detected more reliably, and good inspection capabilities can be obtained.

[0014] In addition, according to the above-mentioned means 1, by using an axicon lens, the entire circumference of the sealing area can be included in one image obtained by the imaging element. Therefore, the entire circumference of the sealing area can be inspected with one image obtained by one imaging, and the inspection efficiency can be improved. Furthermore, the improvement of the inspection efficiency can further increase the productivity (production capacity).

[0015] Furthermore, by using the axicon lens, it is possible to inspect the entire circumference of the sealed area without inserting an inspection device into the tube container, preventing contact between the inspection device and the contents. This makes it possible to more reliably prevent the inspection device from being soiled and the associated deterioration in inspection performance, and ensures good quality in tube products.

[0016] Means 2. The axicon lens has an inner peripheral surface that forms a cylindrical surface extending in the optical axis direction of the axicon lens, while an outer peripheral surface has a central hole truncated cone portion that gradually increases in outer diameter as it moves away from the tube container and forms a truncated cone surface with the optical axis of the axicon lens as its central axis; When the amount of contents filled in the tube container is appropriate, the imaging element is configured to obtain an image in which, from the outside to the inside, an outer edge region corresponding to the outer edge portion of the upper surface of the contents, a seal corresponding region corresponding to the seal region, and a central region corresponding to the central portion of the upper surface of the contents are present in this order, The inspection device described in Means 1 is characterized in that it is provided with a filling amount determination means capable of determining the amount of contents filled into the tube container based on the outer edge side area in the image.

[0017] According to the above-mentioned means 2, the filling amount determination means can determine whether the amount of the contents filled in the tube container is good or bad using the image obtained by the imaging element. For example, it can determine whether the amount of the contents filled is appropriate or not based on the width and area of ​​the contents located in the outer edge side area, the distance from the reference position, etc. Therefore, not only the seal area but also the filling amount can be inspected with one image, so that the efficiency of the inspection can be further improved.

[0018] In addition, the device can be simplified compared to a case in which an inspection device for inspecting the seal area and an inspection device for inspecting the amount of filling of the contents are provided separately, which can reduce manufacturing costs.

[0019] Means 3. An inspection device as described in Means 2, characterized in that it is equipped with a filling presence / absence determination means capable of determining whether or not the tube container is filled with contents based on at least one of the outer edge side region and the central side region in the image.

[0020] According to the above-mentioned means 3, the filling presence / absence determining means can determine whether the tube container is filled with the contents using the image obtained by the imaging element. For example, the presence / absence of the contents can be determined based on whether a portion that generates fluorescence (i.e., the contents) is present in the outer edge side region or the central side region. Therefore, the inspection of the seal area and the inspection of whether the contents are filled can be performed at the same time using a single image, and the efficiency of both inspections can be improved.

[0021] In addition, compared to the case where a separate inspection device is provided to check whether the contents are filled or not, the device can be further simplified, and manufacturing costs can be reduced more effectively.

[0022] Means 4: The inspection device according to means 2 or 3, further comprising a luminance monitoring means for monitoring the luminance of the central region in the image.

[0023] According to the above-mentioned means 4, the brightness of the central region in the image is monitored by the brightness monitoring means. Normally (unless there is an abnormality in the inspection device or contents), the brightness of the central region in the image hardly changes, so by monitoring the brightness of the central region, abnormalities in the inspection device or the like can be detected early. This makes it possible to respond to the abnormality (for example, adjustment or repair of the irradiation means, etc.) at an earlier stage.

[0024] Means 5. The inspection device according to Means 4, further comprising an abnormality response means for automatically taking measures to correct an abnormality when an abnormality occurs in the luminance monitored by the luminance monitoring means.

[0025] According to the above-mentioned means 5, when an abnormality occurs in the brightness of the central region, the abnormality response means automatically performs a response to correct the abnormality. For example, when the brightness of the central region falls below a predetermined brightness threshold, the camera gain, shutter speed, lighting power, etc. are automatically adjusted to normalize the brightness in the image. Therefore, it is possible to suppress a decrease in inspection ability due to the occurrence of an abnormality, and it is possible to more reliably maintain excellent inspection ability. In addition, since the abnormality is automatically corrected, it is possible to reduce the time and effort required for responding to the abnormality.

[0026] Means 6. The inspection apparatus according to Means 1, wherein the imaging lens is an object-side telecentric lens.

[0027] According to the above-mentioned means 6, the resolution in the depth direction of the tube container can be made constant in the obtained image, and the inspection capability (inspection accuracy) can be further improved.

[0028] In addition, the technical matters related to each of the above means may be combined as appropriate. Therefore, for example, the technical matters related to the above means 2 or 3 may be combined with the technical matters related to the above means 6. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 is a perspective view of a tube product. [Diagram 2] FIG. 2 is a perspective view of a tube product with the tube container and the cap separated. [Diagram 3] FIG. 2 is a schematic diagram showing a schematic configuration of a manufacturing apparatus. [Figure 4] FIG. 2 is a block diagram showing a schematic configuration of an inspection device. [Diagram 5] FIG. 1 is a schematic perspective view showing a schematic configuration of an inspection device. [Figure 6] FIG. 2 is a partially cutaway schematic front view showing the general configuration of the inspection device. [Figure 7]FIG. 1 is a schematic cross-sectional view showing positions through an axicon lens of ultraviolet light corresponding to an outer edge portion of the upper surface of the content, ultraviolet light corresponding to a central portion of the upper surface, and ultraviolet light corresponding to an inner surface of a tube container. [Figure 8] 1 is a schematic diagram showing a central region, a seal corresponding region, and an outer edge region in an image. FIG. [Figure 9] 13 is a schematic diagram showing an image when there are no problems with the seal area or contents. FIG. [Figure 10] FIG. 13 is a schematic diagram showing an image when the filling amount of the contents is insufficient. [Figure 11] FIG. 13 is a schematic diagram showing an image when the filling amount of the contents is excessive. [Figure 12] FIG. 13 is a schematic diagram showing an image in which contents are attached to a seal area. [Figure 13] FIG. 13 is a schematic diagram showing an image when no contents are filled. [Figure 14] FIG. 13 is a perspective view of a tube product in another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] An embodiment will be described below with reference to the drawings. First, a tube product having a tube container will be described.

[0031] As shown in Figs. 1 and 2, the tube product 1 is filled with a predetermined content S (see Figs. 5 and 6, etc.) and includes a tube container 2 and a cap 3. The content S is a semi-solid (gel-like) product such as a medicine for external use or a cosmetic cream, and contains petrolatum. In this embodiment, the petrolatum is used as a base material for the content S.

[0032] The tube container 2 has a cylindrical shape with one end closed, and includes a seal portion 21, a shoulder portion 22, and an outlet portion .

[0033] The sealing portion 21 is a portion that closes and seals the opening at one end of the tube container 2. The sealing portion 21 is formed by sealing the opening at one end of the tube container 2 in a flattened and crushed state, for example, by using thermocompression bonding with high-temperature air.

[0034] The shoulder portion 22 is provided on the other end side of the tube container 2 and is a tapered portion whose outer diameter gradually decreases toward the other end of the tube container 2. The shoulder portion 22 is configured to be able to guide the contents S toward the outlet portion 23 side when the side surface of the tube container 2 is pressed.

[0035] The outlet portion 23 has a cylindrical shape continuing to the other end of the shoulder portion 22, constitutes a discharge port for the contents S contained in the tube container 2, and functions as a mounting target for the cap 3. In this embodiment, a helical male screw portion 23a is formed on the outer periphery of the outlet portion 23, and the cap 3 is mounted to the outlet portion 23 by screwing using this male screw portion 23a. Note that a method of mounting the cap 3 may be used other than screwing (for example, a method of fitting the cap 3 onto the outlet portion 23).

[0036] The tube container 2 in this embodiment is a so-called laminated tube. That is, the tube container 2 is formed by cutting a laminated multilayer sheet having gas barrier properties, water vapor barrier properties, etc. to a predetermined size, overlapping and joining both ends of the sheet to form a cylindrical body, and then heat-sealing the parts constituting the shoulder portion 22 and the outlet portion 23 to the cylindrical body. Note that a container other than a laminated tube may be used as the tube container 2. For example, the tube container 2 may be a resin tube in which the cylindrical body, the shoulder portion 22, and the outlet portion 23 are integrally molded by injection molding or the like.

[0037] At least the inner surface of the tube container 2, including a seal area 2x (area with a dotted pattern in Figs. 5 and 6) described later, is made of a material that does not fluoresce in response to ultraviolet light (e.g., polyethylene, etc.). In this embodiment, the entire inner surface of the tube container 2 is made of a material that does not fluoresce in response to ultraviolet light.

[0038] Next, a description will be given of a manufacturing apparatus 40 for manufacturing the above-mentioned tube product 1. As shown in Fig. 3, the manufacturing apparatus 40 includes a conveying device 50, a filling device 60, an inspection device 70, a discharging device 80, a heating device 90, a sealing device 100, and a trimming device 110.

[0039] The conveying device 50 conveys the tube container 2 with the cap 3 attached to the outlet 23 to each of the devices 60, 70, 80, 90, 100, 110 in sequence. The conveying device 50 includes a plurality of holders 51 capable of holding the tube container 2 with one end facing upward, and a driving device (not shown) for moving the holders 51 along a fixed path. By moving the holders 51 with the driving device, the plurality of tube containers 2 set in the holders 51 are intermittently conveyed in a line to each of the devices 60, 70, 80, 90, 100, 110. The driving device also has a function of moving the holder 51 up and down at a predetermined position, and this function causes the tube container 2 to rise and fall at the arrangement position of the filling device 60, the heating device 90, etc. The tube container 2 held by the holder 51 at the most upstream portion has not yet been formed with the seal portion 21, and one end portion is open toward the top.

[0040] The filling device 60 fills the tube container 2 with the contents S through one end opening. The filling device 60 is equipped with an injection tube 61 capable of discharging the contents S from its tip. In the filling device 60, the holder 51 is raised to insert the injection tube 61 into the tube container 2, and the holder 51 is lowered while injecting the contents S into the tube container 2 from the injection tube 61. As the injection tube 61 is pulled out from the one end opening of the tube container 2, a predetermined amount of the contents S is filled into the tube container 2. In this embodiment, the process of filling the tube container 2 with the contents S by the filling device 60 corresponds to the "filling process". Note that when filling the contents S, the contents S may adhere to the seal area 2x of the tube container 2, which will be described below.

[0041] The inspection device 70 inspects the inner surface of the tube container 2, particularly the seal area 2x, for adhesion of the contents S, and inspects the presence and amount of the contents S. The seal area 2x refers to the area of ​​the inner surface of the tube container 2 that is fused when the sealing device 100 seals the opening at one end of the tube container 2 to form the seal portion 21, i.e., the area that is to be sealed. Details of the inspection device 70 will be described later.

[0042] The discharge device 80 discharges the tube container 2 determined to be defective by the inspection device 70 out of the system (out of the conveying path). By providing the discharge device 80, it is possible to more reliably prevent adverse effects (for example, the contents S leaking from the tube container 2 determined to be defective from adhering to the heating device 90, etc.) caused by the tube container 2 determined to be defective being sent to a device (such as the heating device 90) located downstream of the discharge device 80.

[0043] The heating device 90 heats at least the sealing area 2x of the tube container 2, for example, by using high-temperature air. The heating device 90 has a heating unit 91 that can eject high-temperature air (indicated by a solid black arrow in FIG. 3) from the side, and the heating unit 91 is arranged inside the tube container 2 by raising the holder 51. With the heating unit 91 arranged inside the tube container 2, high-temperature air is ejected from the heating unit 91, thereby heating and melting at least the resin in the sealing area 2x. After the sealing area 2x has been heated and melted, the heating unit 91 is pulled out of the tube container 2 by lowering the holder 51.

[0044] The sealing device 100 forms a seal portion 21 at one end of the tube container 2 to seal the opening at one end of the tube container 2. The sealing device 100 includes a pressing unit 101 capable of clamping one end of the tube container 2. The pressing unit 101 then clamps and flattens the heat-melted seal area 2x, thereby crimping the inner surfaces of the seal area 2x together to form the seal portion 21. The sealing device 100 may be provided with a heating function. In this embodiment, the process of sealing the opening at one end of the tube container 2 by the sealing device 100 corresponds to the "sealing process".

[0045] The trimming device 110 performs a trimming process to cut off excess portions of the formed seal portion 21. The tube product 1 finally obtained by the trimming process is packaged in an individual packaging box or shrink film, and then packed in a cardboard box or the like for shipping.

[0046] Next, the inspection device 70 will be described. The inspection device 70 performs an inspection related to adhesion of the contents S to the seal area 2x after the filling device 60 fills the contents S and before the sealing device 100 forms the seal portion 21. As shown in Figs. 4 to 6, the inspection device 70 includes an illumination device 71, an axicon lens 72, an imaging lens 73, a camera 74, and an image processing device 75. In this embodiment, the illumination device 71 constitutes the "illumination means."

[0047] The lighting device 71 is for irradiating the inner surface of the tube container 2 including the sealing area 2x and the upper surface of the filled content S with ultraviolet light. The lighting device 71 is configured as a ring light having a circular shape in a plan view, and is disposed above the tube container 2 at a position surrounding one end opening of the tube container 2 when viewed in a plan view. As long as the amount of the content S filled in the tube container 2 is appropriate, the lighting device 71 irradiates the entire inner circumferential surface of one end side (upper end side) of the tube container 2 and the entire upper surface of the content S from diagonally above the tube container 2 with ultraviolet light. Note that, for example, light having a peak wavelength in the range of 300 nm to 400 nm can be used as the ultraviolet light.

[0048] The axicon lens 72 is disposed vertically above one end opening of the tube container 2 between the tube container 2 and the imaging lens 73, and converts the optical path of the ultraviolet light irradiated from the illumination device 71 and reflected by the contents S into an optical path along the optical axis OA2 direction of the imaging lens 73. The axicon lens 72 has an outer diameter larger than the outer diameter of the one end opening of the tube container 2, and is disposed so as to cover the one end opening from above. The axicon lens 72 is disposed in the immediate vicinity of the tube container 2 (for example, within 15 to 30 mm from the upper end of the tube container 2). Furthermore, the axicon lens 72 is provided with a central hole truncated cone portion 72a on the tube container 2 side.

[0049] The central hole truncated cone portion 72a has an inner peripheral surface that forms a cylindrical surface extending in the direction of the optical axis OA1 of the axicon lens 72, while the outer peripheral surface forms a truncated cone surface with the optical axis OA1 as the central axis, with the outer diameter gradually increasing as it moves away from the tube container 2. In simpler terms, the central hole truncated cone portion 72a has a shape in which a circular hole is provided in the center of a cone in a plan view. The inner diameter of the central hole truncated cone portion 72a (the inner diameter of the hole provided in the center) is configured to be smaller than the inner diameter of the opening on one end side of the tube container 2.

[0050] By configuring the axicon lens 72 as described above in relation to the tube container 2 and by appropriately setting the inclination angle of the truncated cone surface with respect to the optical axis OA1, when the amount of the contents S filled in the tube container 2 is appropriate, ultraviolet light and the like corresponding to the outer edge portion of the upper surface of the contents S reaches the camera 74 (an image sensor 74a described later) as follows: That is, the ultraviolet light corresponding to the outer edge portion of the upper surface of the contents S reaches the camera 74 (an image sensor 74a described later) through the outer periphery side of the truncated cone surface of the central hole truncated cone portion 72a, the ultraviolet light corresponding to the inner surface of the tube container 2 including the sealing area 2x reaches the inner periphery side of the truncated cone surface, and the ultraviolet light corresponding to the central portion of the upper surface of the contents S reaches the camera 74 (an image sensor 74a described later) through the central hole portion of the central hole truncated cone portion 72a (see FIG. 7).

[0051] As a result, the image obtained by the camera 74 (the image sensor 74a described later) shows, from the outside to the inside, the outer edge side area AS1, the seal corresponding area Ax, and the central side area AS2 in this order (see FIG. 8).

[0052] The outer edge side area AS1 is an area (area with a checkered pattern in FIG. 8) corresponding to the outer edge side portion of the upper surface of the contents S filled in the tube container 2. The outer edge side area AS1 is used to determine whether the amount of the contents S filled in the tube container 2 is acceptable or not.

[0053] The sealable area Ax is an area (area marked with a dotted pattern in FIG. 8) corresponding to the sealable area 2x in the tube container 2. The sealable area Ax is used to determine whether or not the contents S are attached to the sealable area 2x.

[0054] The central region AS2 is a region (hatched region in FIG. 8) corresponding to a central portion of the upper surface of the contents S filled in the tube container 2. The central region AS2 is used to determine whether the contents S are filled in the tube container 2 or not.

[0055] In this way, by using the axicon lens 72, multiple areas used for inspecting the tube container 2 and the contents S are included in a single image obtained by the camera 74 (the image sensor 74a described later).

[0056] The imaging lens 73 is for forming an image of the ultraviolet light irradiated from the illumination device 71, reflected off the contents S, and transmitted through the axicon lens 72 on an image pickup element 74a (described later) of the camera 74. The imaging lens 73 is disposed between the axicon lens 72 and the camera 74, and an optical axis OA2 of the imaging lens 73 coincides with an optical axis OA1 of the axicon lens 72.

[0057] The imaging lens 73 is configured to be an object-side telecentric optical system. That is, the imaging lens 73 is configured so that the optical axis OA2 and the principal ray are parallel to each other on the tube container 2 side.

[0058] The camera 74 is disposed vertically above the imaging lens 73, and is composed of a camera (e.g., a CCD camera or a CMOS camera) that is sensitive to at least the ultraviolet light irradiated from the illumination device 71. The camera 74 is configured so that the shutter speed and camera gain can be remotely controlled. The camera 74 also includes an image sensor 74a. The camera 74 may have an aperture for adjusting the ultraviolet light imaged on the image sensor 74a by limiting the amount of ultraviolet light entering the image sensor 74a from the imaging lens 73.

[0059] The imaging element 74a is composed of, for example, a CCD area sensor or a CMOS sensor, and captures an image of ultraviolet light irradiated from the illumination device 71. The imaging element 74a has a light receiving surface on which a plurality of light receiving elements are two-dimensionally arranged in a matrix, and the light receiving surface is set to be perpendicular to the optical axis OA2. An image (image data) is acquired by the imaging element 74a as a result of imaging processing by the camera 74. The acquired image (image data) is sent to the image processing device 75.

[0060] The image (image data) obtained by the camera 74 (image pickup element 74a) is luminance image data having information on the luminance of each pixel. As described above, since the contents S contain Vaseline, the contents S fluoresce when exposed to ultraviolet light. On the other hand, the inner surface of the tube container 2 including the seal area 2x is made of a material that does not fluoresce when exposed to ultraviolet light, and therefore the inner surface does not fluoresce when exposed to ultraviolet light.

[0061] Therefore, if there is no problem with the filling amount of the contents S, the outer edge region AS1 of the obtained luminance image data will have a high luminance portion BA1 with a luminance equal to or greater than a predetermined value due to the fluorescence generated on the outer edge side of the upper surface of the contents S (see FIG. 9. In FIG. 9, the high luminance portion BA1 is shown in white, and the low luminance portion is shown in a dotted pattern). The distance K1 of this high luminance portion BA1 from a predetermined reference position (for example, the center of the central region AS2) will be within a predetermined range.

[0062] Furthermore, if there is no problem with the adhesion of the contents S to the sealing area 2x, such as if the contents S are not attached to the sealing area 2x, the seal corresponding area Ax of the luminance image data will not have any high luminance areas larger than a predetermined area, and the low luminance areas Dx will spread over almost the entire area (see Figure 9).

[0063] Furthermore, when the contents S are filled, a roughly circular high-brightness portion BA2 having a brightness equal to or greater than a predetermined value will be present in the central region AS2 of the brightness image data due to fluorescence generated at the center of the top surface of the contents S (see FIG. 9).

[0064] On the other hand, when the amount of the contents S is too small or too large, that is, when there is a problem with the amount of the contents S, in the outer edge region AS1 of the luminance image data, the distance K1 from a predetermined reference position (for example, the center of the central region AS2) to the high luminance portion BA1 becomes too large or too small (see Figs. 10 and 11). Note that when the distance K1 from the reference position to the high luminance portion BA1 is too large (the state shown in Fig. 10), the contents S are too far away from the opening on one end side of the tube container 2, and the amount of the contents S is insufficient. On the other hand, when the distance from the reference position to the high luminance portion BA1 is too small (the state shown in Fig. 11), the contents S are too close to the opening on one end side of the tube container 2, and the amount of the contents S is too large.

[0065] Furthermore, when contents S are attached to the seal area 2x, the fluorescence generated by the attached contents S causes a high-brightness portion Bx of a predetermined area or more to appear in the low-brightness portion Dx in the seal corresponding area Ax of the brightness image data (see Figure 12).

[0066] In addition, when the contents S are not filled, the central region AS2 of the luminance image data does not have a high luminance portion BA2, and the entire central region AS2 has low luminance (see FIG. 13).

[0067] In this embodiment, the tube container 2 has a lamination line 2h (see FIG. 5) formed by overlapping and joining both ends of the laminated multilayer sheet, but since the inner surface of the tube container 2 is made of a material that does not fluoresce in response to ultraviolet light, this lamination line 2h does not appear at all or is barely visible in the image. Therefore, forming the inner surface of the tube container 2 from a material that does not fluoresce in response to ultraviolet light is also effective in preventing a decrease in inspection accuracy due to the lamination line 2h.

[0068] The image processing device 75 comprises a computer including a CPU (Central Processing Unit) that executes predetermined arithmetic processing, a ROM (Read Only Memory) that stores various programs and fixed value data, a RAM (Random Access Memory) that temporarily stores various data when executing various arithmetic processing, and peripheral circuits for these.

[0069] 4, the image processing device 75 functions as various functional units such as a main control unit 751, a lighting control unit 752, a camera control unit 753, a display control unit 754, an image acquisition unit 755, a determination unit 756, a brightness monitoring unit 757, and an abnormality response unit 758, which will be described later, by the CPU operating in accordance with various programs. In this embodiment, the brightness monitoring unit 757 constitutes the "brightness monitoring means", and the abnormality response unit 758 constitutes the "abnormality response means".

[0070] However, the various functional units are realized through cooperation of various hardware such as the CPU, ROM, RAM, etc., and there is no need to clearly distinguish between functions realized by hardware and functions realized by software, and some or all of these functions may be realized by hardware circuits such as ICs.

[0071] Furthermore, the image processing device 75 is provided with an input unit 75a consisting of a keyboard, mouse, touch panel, etc., a display unit 75b consisting of an LCD display or the like and equipped with a display screen capable of displaying various types of information, a memory unit 75c capable of storing various types of data, programs, calculation results, inspection results, etc., and a communication unit 75d capable of transmitting and receiving various types of data to and from the outside.

[0072] First, prior to describing the various functional units constituting the image processing device 75, the display unit 75b, the storage unit 75c, and the communication unit 75d will be described.

[0073] The display unit 75b is configured to be able to display various information stored in the storage unit 75c. Therefore, the display unit 75b can display an image obtained by the camera 74, thresholds used for pass / fail judgment (for example, thresholds L1, S1, D1, etc. described later), pass / fail judgment results, etc.

[0074] The storage unit 75c is composed of a HDD (Hard Disk Drive) or SSD (Solid State Drive), and stores, for example, images (image data) and pass / fail judgment results. The storage unit 75c also stores brightness thresholds L1 and L2, area threshold S1, and distance thresholds D1 and D2, which are thresholds used in pass / fail judgment, as well as information for identifying the above-mentioned regions AS1, AS2, and Ax. <L2であり、D1<D2である。

[0075] The communication unit 75d is equipped with a wireless communication interface conforming to a communication standard such as a wired LAN (Local Area Network) or a wireless LAN, and is configured to be able to transmit and receive various data to and from the outside. For example, the result of a quality determination performed by a seal area quality determination unit 756a (described later) is output to the outside (e.g., the discharge device 80) via the communication unit 75d.

[0076] Next, the above-mentioned various functional units constituting the image processing device 75 will be described in more detail.

[0077] The main control unit 751 is a functional unit that controls the entire inspection device 70, and is configured to be able to transmit and receive various signals to and from other functional units such as a lighting control unit 752 and a camera control unit 753.

[0078] The lighting control unit 752 is a functional unit that controls the lighting device 71 based on a command signal from the main control unit 751.

[0079] The camera control unit 753 is a functional unit that controls the camera 74, and controls the image capturing timing, camera gain, shutter speed, and the like by the camera 74 based on a command signal from the main control unit 751.

[0080] The display control unit 754 controls the display contents on the display unit 75b based on the information stored in the storage unit 75c.

[0081] The image acquisition unit 755 is a functional unit for taking in an image (luminance image data) captured and acquired by the camera 74.

[0082] The judgment unit 756 is a functional unit that judges the quality of the adhesion of the contents S to the seal area 2x, and the filling amount and presence or absence of the contents S, based on the luminance image data obtained by the camera 74. The judgment unit 756 includes a seal area quality judgment unit 756a, a filling amount judgment unit 756b, and a filling presence or absence judgment unit 756c. In this embodiment, the seal area quality judgment unit 756a constitutes the "seal area quality judgment means", and similarly, the filling amount judgment unit 756b constitutes the "filling amount judgment means", and the filling presence or absence judgment unit 756c constitutes the "filling presence or absence judgment means".

[0083] The seal area quality determination unit 756a determines the quality of the seal area 2x with respect to the attachment of the contents S based on the image obtained by imaging with the camera 74 (image pickup element 74a). More specifically, the seal area quality determination unit 756a identifies the seal corresponding area Ax in the image based on the information stored in the storage unit 75c, and identifies the high brightness part Bx (i.e., the part corresponding to the attached contents S) having a brightness higher than the brightness threshold L1 in the seal corresponding area Ax. Then, if the area (number of pixels) of the identified high brightness part Bx is less than the area threshold S1, the seal area quality determination unit 756a determines that there is no problem with the attachment of the contents S to the seal area 2x and determines the seal area 2x as "good". On the other hand, if the area (number of pixels) of the high brightness part Bx is equal to or greater than the area threshold S1, the seal area quality determination unit 756a determines that the contents S are attached to the seal area 2x and determines the seal area 2x as "bad".

[0084] When the sealing area 2x is judged to be “defective”, a signal indicating that the sealing area 2x has been judged to be defective is sent from the image processing device 75 to the discharge device 80 via the communication unit 75d. Upon receiving this signal, the discharge device 80 discharges the tube container 2 related to the defective judgment to the outside of the system.

[0085] The filling amount determination unit 756b determines the amount of the contents S filled in the tube container 2 based on the outer edge side area AS1 in the image. More specifically, the filling amount determination unit 756b identifies the outer edge side area AS1 in the image based on the information stored in the storage unit 75c, and identifies a high brightness portion BA1 (i.e., a portion corresponding to the contents S) having a brightness higher than the brightness threshold L1 in the outer edge side area AS1. Then, the filling amount determination unit 756b calculates a value (distance correspondence value) corresponding to the distance K1 from a predetermined reference position (for example, the center of the central side area AS2) to the high brightness portion BA1. In this embodiment, the average distance of the distance K1 is calculated as the distance correspondence value. Note that the maximum distance or minimum distance from the reference position to the high brightness portion BA1 may be calculated as the distance correspondence value. Of course, a value related to the area or width of the high brightness portion BA1 may be calculated as the distance correspondence value. In addition, the opening of one end side of the tube container 2 may be used as the reference position.

[0086] Then, if the calculated distance corresponding value is greater than or equal to the distance threshold D1 and less than or equal to the distance threshold D2, the filling amount determination unit 756b determines that the filling amount of the contents S is appropriate and determines that the filling amount of the contents S is "good."

[0087] On the other hand, when the calculated distance corresponding value is less than the distance threshold D1, the filling amount determining unit 756b determines that the filling amount of the contents S is excessive and determines that the filling amount of the contents S is "defective". When the calculated distance corresponding value is greater than the distance threshold D2, the filling amount determining unit 756b determines that the filling amount of the contents S is insufficient and determines that the filling amount of the contents S is "defective". When the filling amount of the contents S is determined to be "defective", a signal indicating that a defective determination has been made is sent from the image processing device 75 to the discharge device 80, and the discharge device 80 discharges the tube container 2 related to the defective determination to the outside of the system.

[0088] The filling presence / absence determining unit 756c determines whether the tube container 2 is filled with the contents S based on the central region AS2 in the image. More specifically, the filling presence / absence determining unit 756c identifies the central region AS2 in the image based on the information stored in the storage unit 75c, and determines whether a high brightness portion BA2 having a brightness higher than the brightness threshold value L1 (i.e., a portion corresponding to the contents S) is present in the central region AS2.

[0089] When the high-brightness portion BA2 exists in the central region AS2, the filling presence / absence determining unit 756c determines that the contents S are filled and determines whether the contents S are filled as "good". On the other hand, when the high-brightness portion BA2 does not exist in the central region AS2, the filling presence / absence determining unit 756c determines that the contents S are not filled and determines whether the contents S are filled as "bad". When the filling presence / absence of the contents S is determined to be "bad", a signal indicating that a bad determination has been made is sent from the image processing device 75 to the discharge device 80, and the discharge device 80 discharges the tube container 2 related to the bad determination out of the system.

[0090] The discharge device 80 may be configured to discharge the tube container 2 to a different destination depending on the type of defect judgment (i.e., depending on whether the defect judgment is related to adhesion of the contents S to the sealing area 2x, the filling amount of the contents S, or the presence or absence of filling of the contents S). Furthermore, when the defect judgment is related to adhesion of the contents S to the sealing area 2x or the filling amount of the contents S, the discharged tube container 2 may be configured to be held in an upright state with one end opening facing upward (i.e., the tube container 2 is maintained in the same state as during inspection).

[0091] The luminance monitoring unit 757 monitors the luminance of the central region AS2 in the image. In this embodiment, the luminance monitoring unit 757 measures the luminance (maximum luminance) of the central region AS2 in the image (i.e., the high luminance portion BA2), and determines whether the measured luminance is equal to or greater than the luminance threshold value L2. If the measured luminance is equal to or greater than the luminance threshold value L2, the luminance monitoring unit 757 determines that there is no abnormality in the luminance.

[0092] On the other hand, if the measured luminance is less than the luminance threshold value L2 in a predetermined number of tube containers 2 consecutively, the luminance monitoring unit 757 determines that there is an abnormality in the luminance due to, for example, a drop in the output of the lighting device 71. If the luminance monitoring unit 757 determines that there is an abnormality in the luminance, it sends a signal to that effect (luminance abnormality signal) to the abnormality handling unit 758. Here, since the luminance threshold value L2 is set to be greater than the luminance threshold value L1 as described above, even if the measured luminance is slightly below the luminance threshold value L2, basically, this does not hinder the pass / fail judgment by each of the judgment units 756a, 756b, and 756c.

[0093] Incidentally, when it is determined that there is an abnormality in the brightness, the brightness monitoring unit 757 may be configured to be able to notify the fact to the outside using, for example, the display unit 75b etc. In such a configuration, it is not necessarily necessary to provide the abnormality response unit 758, and it is also not necessary to send a brightness abnormality signal from the brightness monitoring unit 757 to the abnormality response unit 758.

[0094] When an abnormality occurs in the luminance monitored by the luminance monitoring unit 757 (when a luminance abnormality signal is received in this embodiment), the abnormality response unit 758 automatically takes action to correct the abnormality. In this embodiment, when the abnormality response unit 758 receives a luminance abnormality signal, it performs a predetermined abnormality response process. Examples of the abnormality response process include a process of increasing the output (illumination power) of the lighting device 71 via the main control unit 751 and the lighting control unit 752, and a process of increasing the camera gain and slowing down the shutter speed of the camera 74 via the main control unit 751 and the camera control unit 753.

[0095] As described above in detail, according to this embodiment, the inspection is performed at a stage before the opening on one end side of the tube container 2 is sealed to form the seal portion 21, that is, at a stage before the seal portion 21 is formed at which leakage of the contents S is likely to occur, so that it is possible to make it more difficult for the inspection device 70 to be soiled by the leaked contents S. This makes it possible to almost completely eliminate the need for cleaning to remove the leaked contents S, thereby improving productivity (production capacity).

[0096] Furthermore, while the contents S contain Vaseline, the inner surface of the tube container 2 is formed of a material that does not fluoresce in response to ultraviolet light. Therefore, while the ultraviolet light irradiated from the lighting device 71 can cause the contents S to fluoresce, it is possible to prevent the sealing area 2x from fluorescing. This makes it possible to make the sealing area 2x and the contents S more clearly distinguishable in the image obtained by the imaging element 74a. As a result, the contents S attached to the sealing area 2x can be detected more reliably, and good inspection capabilities can be obtained.

[0097] In addition, by using the axicon lens 72, the entire circumference of the seal area 2x can be included in one image obtained by the imaging element 74a. Therefore, the entire circumference of the seal area 2x can be inspected with one image obtained by one imaging, and the inspection efficiency can be improved. Furthermore, the improved inspection efficiency can further increase productivity (production capacity).

[0098] Furthermore, by using the axicon lens 72, it is possible to inspect the entire circumference of the seal area 2x without inserting the inspection device 70 into the tube container 2, thereby preventing contact between the inspection device 70 and the contents S. This makes it possible to more reliably prevent the inspection device 70 from being soiled and the associated deterioration in inspection performance, and also ensure good quality of the tube product 1.

[0099] Additionally, the filling amount determining unit 756b can use the image obtained by the imaging element 74a to determine whether the amount of the contents S filled in the tube container 2 is good or bad. Therefore, not only the seal area 2x but also the filling amount can be inspected with one image, so that the efficiency of the inspection can be further improved.

[0100] In addition, the filling presence / absence determining unit 756c can determine whether the tube container 2 is filled with the contents S by using the image obtained by the imaging element 74a. Therefore, the inspection of the seal area 2x and the inspection of whether the contents S are filled can be performed at the same time using a single image, thereby improving the efficiency of both inspections.

[0101] Furthermore, the device (manufacturing device 40) can be simplified compared to a case where an inspection device for inspecting the seal area 2x, an inspection device for inspecting the amount of the contents S filled, and an inspection device for inspecting whether the contents S is filled are separately provided. This makes it possible to effectively reduce manufacturing costs.

[0102] Furthermore, the brightness of the central region AS2 in the image is monitored by the brightness monitoring unit 757. Normally (unless there is an abnormality in the inspection device 70 or the contents S), the brightness of the central region AS2 hardly changes, so by monitoring the brightness of the central region AS2, it is possible to detect an abnormality in the inspection device 70 or the like at an early stage. This makes it possible to respond to the abnormality (for example, adjust or repair the lighting device 71, etc.) at an earlier stage.

[0103] In addition, in this embodiment, when an abnormality occurs in the luminance of the central region AS2, the abnormality handling unit 758 automatically handles the abnormality to correct the abnormality. Therefore, it is possible to suppress a decrease in inspection capability due to the occurrence of an abnormality, and it is possible to more reliably maintain excellent inspection capability. Furthermore, because the abnormality is automatically corrected, it is possible to reduce the time and effort required for handling the abnormality.

[0104] Furthermore, since the imaging lens 73 is an object-side telecentric lens, it is possible to make the resolution of the obtained image constant in the depth direction of the tube container 2. As a result, it is possible to further improve the inspection capability (inspection accuracy).

[0105] The present invention is not limited to the above-described embodiment, and may be implemented as follows: Of course, other applications and modifications not exemplified below are also possible.

[0106] (a) In the above embodiment, the filling presence / absence determination unit 756c determines whether the tube container 2 is filled with the contents S based on the central region AS2, but may determine whether the tube container 2 is filled with the contents S based on the outer edge region AS1. For example, the filling presence / absence determination unit 756c may determine whether the tube container 2 is filled with the contents S based on whether an area with a higher brightness than the brightness threshold value L1 exists in the outer edge region AS1. Of course, the filling presence / absence determination unit 756c may determine whether the tube container 2 is filled with the contents S based on both the central region AS2 and the outer edge region AS1.

[0107] (b) In the above embodiment, the sealed portion 21 of the tube container 2 is formed by sealing one open end of the tube container 2 in a flattened state. In contrast, as shown in Fig. 14, the sealed portion 21 of the tube container 2 may be formed by folding the opening of one end of the tube container 2.

[0108] (c) In the above embodiment, the heating device 90 is configured to heat and melt the tube container 2 by high-temperature air, but the heating device 90 may heat and melt the tube container 2 by means of something other than high-temperature air. Therefore, the heating device 90 may heat and melt the tube container 2 by using, for example, ultrasonic waves.

[0109] (d) In the above embodiment, the determination unit 756 includes the filling amount determination unit 756b and the filling presence / absence determination unit 756c, but may include only one of the two determination units 756b, 756c. Moreover, the determination unit 756 may not include both the determination units 756b, 756c, and may include only the seal area quality determination unit 756a.

[0110] (e) In the above embodiment, the judgment unit 756 includes judgment units 756b and 756c for inspecting the amount of the contents S filled and whether or not it is filled. In addition to these, the judgment unit 756 may include a foreign matter adhesion judgment unit for judging the quality of foreign matter (particularly, foreign matter that does not generate fluorescence in ultraviolet light) attached to the upper surface of the contents S based on an image obtained by imaging by the imaging element 74a. In this case, based on one image, inspection of the seal area 2x and the contents S as well as inspection of the attachment of foreign matter can be performed. This can improve the inspection efficiency and further simplify the manufacturing device 40. Note that a foreign matter adhesion judgment unit may be provided instead of at least one of the judgment units 756b and 756c.

[0111] (f) In the above embodiment, the contents S are semi-solid, but the contents S may be liquid.

[0112] (g) The inspection device 70 may include a pre-pressing section that can pinch one end of the tube container 2 in the same manner as when the seal portion 21 is formed after the filling device 60 fills the contents S and before the camera 74 (imaging element 74a) captures an image. Then, after the one end of the tube container 2 is temporarily pinched by the pre-pressing section, the camera 74 (imaging element 74a) may capture an image in a state where the one end of the tube container 2 is opened again.

[0113] By sandwiching the tube container 2 with the pre-pressing portion, it becomes possible to inspect the adhesion of the contents S to the seal area 2x, taking into consideration the spreading (movement) of the contents S when forming the seal portion 21. This can further improve the inspection accuracy. [Explanation of symbols]

[0114] 1...tube product, 2...tube container, 2x...sealed area, 21...sealed portion, 70...inspection device, 71...illumination device (irradiation means), 72...axicon lens, 72a...central hole truncated cone portion, 73...imaging lens, 74a...image sensor, 756a...sealed area pass / fail determination section (sealed area pass / fail determination means), 756b...filling amount determination section (filling amount determination means), 756c...filling presence / absence determination section (filling presence / absence determination means), 757...luminance monitoring section (luminance monitoring means), 758...abnormality response section (abnormality response means), AS1...outer edge side region, AS2...central side region, Ax...sealed corresponding area, S...contents.

Claims

1. The inspection device is used in manufacturing a tube product in which a plurality of tube containers are filled with contents by carrying out a filling process of filling the tube containers with contents through openings at the ends of the tube containers while arranging and transporting the tube containers, and a sealing process of sealing the openings, and is capable of inspecting a seal area, which is an area of ​​the inner surface of the tube container that is to be sealed in the sealing process, At least an inner surface of the tube container including the sealing area is formed of a material that does not generate fluorescence when exposed to ultraviolet light, The content contains petrolatum, an irradiation means for irradiating an inner surface of the tube container including at least the sealing area with ultraviolet light after the filling step and before the sealing step; an image pickup element capable of picking up an image of the ultraviolet light irradiated from the irradiation means; an imaging lens that forms an image on the image sensor using ultraviolet light that is irradiated from the irradiating means and reflected by the contents; an axicon lens that is disposed vertically above the opening of the tube container between the tube container and the imaging lens, and is configured to convert an optical path of the ultraviolet light that is irradiated from the irradiation means and reflected off the contents into an optical path along an optical axis direction of the imaging lens; and a seal area quality determination means for determining the quality of the seal area with respect to adhesion of contents based on an image obtained by imaging with the imaging element.

2. the axicon lens has an inner peripheral surface that forms a cylindrical surface extending in the optical axis direction of the axicon lens, while an outer peripheral surface has a central hole truncated cone portion that gradually increases in outer diameter as it moves away from the tube container and forms a truncated cone surface with the optical axis of the axicon lens as its central axis; When the amount of contents filled in the tube container is appropriate, the imaging element is configured to obtain an image in which, from the outside to the inside, an outer edge region corresponding to the outer edge portion of the upper surface of the contents, a seal corresponding region corresponding to the seal region, and a central region corresponding to the central portion of the upper surface of the contents are present in this order, The inspection device according to claim 1 , further comprising a filling amount determination unit capable of determining a filling amount of the contents in the tube container based on the outer edge side area in the image.

3. The inspection device according to claim 2, further comprising a filling presence / absence determination means capable of determining whether or not the tube container is filled with contents based on at least one of the outer edge side region and the central side region in the image.

4. 4. The inspection apparatus according to claim 2, further comprising a luminance monitoring means for monitoring the luminance of the central region in the image.

5. 5. The inspection apparatus according to claim 4, further comprising an abnormality response means for automatically taking measures to correct an abnormality when an abnormality occurs in the luminance monitored by said luminance monitoring means.

6. 2. The inspection apparatus according to claim 1, wherein the imaging lens is an object-side telecentric lens.

Images