Seal means abnormality detection system and blister packaging machine

Abstract

To provide seal means abnormality detection system capable of detecting an abnormality of a sealing means more easily and more accurately by using only a detection result from attachment state inspection means.SOLUTION: A seal device abnormality detection system 50 as seal means abnormality detection system includes: a post-sealing inspection device 60 serving as attachment state inspection means for detecting a seal abnormal portion; a frequency acquisition unit 71 configured to derive an abnormal occurrence interval that correlates with the interval between seal abnormal portions detected by the post-sealing inspection device 60 and to acquire, for each abnormal occurrence interval, the derivation frequency of the abnormal occurrence interval; and a periodic abnormality determination unit 72 configured to determine, on the basis of the derivation frequency acquired by the frequency acquisition unit 71, whether or not there is a periodic abnormality related to an attachment state of a cover film 4 to a container film 3. On the basis of the determination result of the periodic abnormality determination unit 72, the presence or absence of an abnormality in a sealing device 25 serving as seal means is determined.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a sealing means abnormality detection system for detecting an abnormality in a sealing means for attaching a cover film to a container film, and a blister packaging machine having the system. [Background technology]

[0002] A press-through pack (PTP) sheet is known as a blister sheet generally used in the pharmaceutical field, etc. A PTP sheet comprises a container film having a pocket portion in which contents (e.g., tablets) are placed, and a cover film attached to the container film so as to seal the opening side of the pocket portion.

[0003] The blister sheets described above can be manufactured by a blister packaging machine, which has a means for forming pockets in a strip-shaped container film, a means for filling the pockets with contents, a means for attaching a strip-shaped cover film to the container film, and a means for punching out the strip-shaped blister film, which is the container film with the cover film attached, into blister sheets.

[0004] A known means (sealing means) for attaching a cover film to a container film includes a film receiving roll having a number of recesses formed on its outer periphery capable of accommodating pockets, and a heating roll whose outer periphery is pressed against the outer periphery of the film receiving roll. The heating roll is capable of generating heat using an electric heater or the like provided inside. The container film and cover film are then passed between the two rolls in a superimposed state, thereby attaching the cover film to the container film.

[0005] The surface of the heating roll may be provided with a mesh-like ridge (protrusion). By providing the ridge, when the cover film is attached to the container film, the ridge bites into the cover film and the container film, resulting in the formation of a mesh-like seal on the blister sheet, enabling the cover film to be firmly sealed to the container film.

[0006] However, foreign matter originating from components of the cover film (e.g., a resin layer) may adhere to the sealing means (e.g., the surface of a heating roll, etc.), causing abnormalities in the attachment of the cover film to the container film. In terms of improving productivity, it is preferable to be able to detect abnormalities in the sealing means early and therefore take appropriate measures, such as cleaning the sealing means, early on.

[0007] Known blister packaging machines capable of detecting abnormalities (faults) in the sealing means include a foreign matter inspection means (fifth inspection device) that detects tablet powder, foreign matter, hair, etc. adhering to the blister film, and an attachment state inspection means (sixth inspection device) that detects abnormalities in the attachment state of the cover film to the container film (abnormal sealing portion) (see, for example, Patent Document 1, etc.). In this blister packaging machine, if the positional information of the tablet powder, etc. detected by the foreign matter inspection means does not match the positional information of the abnormal sealing portion detected by the attachment state inspection means, it is determined that an abnormality has occurred in the sealing means. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-206711 Summary of the Invention [Problem to be solved by the invention]

[0009] However, the above-mentioned blister packaging machine needs to be provided with at least two inspection means to detect abnormalities in the sealing means, which may lead to a complicated device.

[0010] Furthermore, the foreign body inspection means may erroneously detect a portion where the cover film is not properly attached to the container film (an abnormally sealed portion) as tablet powder, a foreign body, etc. If such an erroneous detection occurs, the two pieces of position information will match, making it impossible to detect an abnormality in the sealing means.

[0011] The present invention has been made in consideration of the above circumstances, and its purpose is to provide a sealing means abnormality detection system etc. that can more easily and accurately detect abnormalities in the sealing means by using only the detection results from the attachment state inspection means. [Means for solving the problem]

[0012] The following describes each of the means suitable for achieving the above object, with specific effects of the corresponding means added as necessary.

[0013] Means 1. A filling means for filling contents into a pocket formed in a strip-shaped container film; a sealing means having two predetermined rolls, the cover film being fed between the two rolls in a state where the cover film is superimposed on the container film, thereby attaching the cover film to the container film so as to close the opening side of the pocket portion filled with the contents by the filling means; a separating means for separating a blister sheet from a strip-shaped blister film formed by attaching the cover film to the container film; A sealing means abnormality detection system for detecting an abnormality in the sealing means relating to attachment of the cover film to the container film, which is used in a blister packaging machine comprising: an attachment state inspection means for detecting an abnormal seal portion of the blister film, which is a portion where an abnormality exists in the attachment state of the cover film to the container film; a frequency acquisition means for deriving an abnormality occurrence interval that correlates with the distance along the longitudinal direction of the blister film from the abnormal sealing portion detected by the attachment state inspection means to the next abnormal sealing portion detected by the attachment state inspection means after the abnormal sealing portion, and for acquiring the frequency of the abnormality occurrence interval for each abnormality occurrence interval; a periodic abnormality determination means for determining whether or not there is a periodic abnormality in the attachment state of the cover film to the container film based on the derived frequency acquired by the frequency acquisition means; A sealing means abnormality detection system characterized by comprising a sealing means abnormality judgment means that judges whether or not there is an abnormality in the sealing means related to the attachment of the cover film to the container film based on the judgment results by the periodic abnormality judgment means.

[0014] In addition, the "derivation frequency" in "obtaining the derivation frequency of the abnormality occurrence interval for each abnormality occurrence interval" may include, for example, the total number of derivations of the abnormality occurrence interval or the derivation ratio calculated for each abnormality occurrence interval.

[0015] The sealing means attaches the container film and cover film by feeding them between two rolls. Therefore, if an abnormality in the sealing means causes an abnormality in the attachment of the cover film to the container film (an abnormally sealed portion), this abnormally sealed portion usually occurs periodically along the longitudinal direction of the blister film.

[0016] In view of this, according to the above-mentioned means 1, the frequency acquisition means derives an abnormality occurrence interval that correlates with the distance from the sealing abnormality portion to the next sealing abnormality portion, and acquires the derived frequency of the abnormality occurrence interval for each abnormality occurrence interval.The periodic abnormality determination means then determines whether or not a periodic abnormality has occurred in the attachment state of the cover film to the container film based on the derived frequency acquired by the frequency acquisition means.Furthermore, the sealing means abnormality determination means determines whether or not there is an abnormality in the sealing means based on the determination result by the periodic abnormality determination means.

[0017] If the frequency of the calculated abnormality interval for a specific abnormality occurrence interval is significantly higher than the frequencies of the calculated abnormality intervals for other abnormality occurrence intervals, there is a high probability that the sealing abnormality occurs periodically. Therefore, by using the calculated frequency, the periodic abnormality determination means can accurately determine whether or not there is a periodic abnormality in the attachment state of the cover film to the container film. As a result, the sealing means abnormality determination means, which uses this determination result, can more easily and accurately determine whether or not there is an abnormality in the sealing means.

[0018] Furthermore, according to the above-mentioned means 1, it is possible to determine whether or not there is an abnormality in the sealing means by using only the detection results from the attachment state inspection means. In other words, to determine whether or not there is an abnormality in the sealing means, it is not necessary to provide two inspection means, and only one inspection means is sufficient. Therefore, it is possible to more reliably prevent the system from becoming complicated, and to reduce the costs associated with the manufacturing and maintenance of the system.

[0019] Means 2. The blister film is configured so that the pre-sheet portions to be cut off by the cutting means to become the blister sheets are aligned along the longitudinal direction of the blister film, the attachment state inspection means is capable of detecting the abnormal seal portion for each of the intended sheet portions, The sealing means abnormality detection system described in means 1 is characterized in that the frequency acquisition means is configured to derive the number of the sheet intended portions corresponding to the interval from the sealing abnormality portion detected by the attachment state inspection means to the sealing abnormality portion detected by the attachment state inspection means next to the sealing abnormality portion.

[0020] It is conceivable to simply use the "length" of the blister film along its longitudinal direction as the interval at which abnormalities occur. In this case, the "length" can be obtained based on the circumference of the roll used to attach the cover film to the container film. However, the surface of the roll gradually wears away during the production of blister sheets, and the roll surface is polished or processed (for example, knurled) as needed, so the circumference of the roll is not constant but fluctuates. Therefore, in order to determine the "length" from the circumference of the roll and use this "length" as the interval at which abnormalities occur, it becomes necessary to perform the cumbersome task of determining and managing the circumference of the roll.

[0021] In contrast, according to the above-mentioned means 2, the frequency acquisition means derives the number of sheets corresponding to the distance from one abnormal sealing portion to the next abnormal sealing portion as the abnormality interval. Therefore, the abnormality interval can be derived without using the circumferential length of the roll, and an increase in the workload can be more reliably prevented.

[0022] Furthermore, according to the above-mentioned means 2, since it is configured to be able to detect an abnormal sealing portion for each intended sheet portion, it is possible to easily obtain the number of intended sheet portions as the abnormality occurrence interval, thereby reducing the processing load when obtaining the abnormality occurrence interval.

[0023] Furthermore, according to the above-mentioned means 2, since it is possible to detect the defective seal portion for each blister sheet, it becomes easier to sort out the quality of each blister sheet.

[0024] Means 3. The sealing means abnormality detection system described in Means 2 is characterized in that the periodic abnormality determination means is configured to compare the derived frequency at the abnormality occurrence interval obtained by subtracting 1 from the abnormality occurrence interval at which the derived frequency is maximum as a reference interval, with the derived frequency at the abnormality occurrence interval obtained by adding 1 to the reference interval, and to determine whether or not there is a periodic abnormality based on the value obtained by adding the larger of these two derived frequencies to the derived frequency at the reference interval.

[0025] The width of the intended sheet portion (the length of the intended sheet portion along the longitudinal direction of the blister film) varies depending on the design of the blister sheet, the size of the contents, and other factors. Furthermore, as mentioned above, the circumferential length of a roll is not necessarily constant. Therefore, it is rare for the circumferential length of a roll to be an integer multiple of the width of the intended sheet portion. Therefore, when the number of intended sheet portions is used as the abnormality occurrence interval as in the above-mentioned method 2, even when periodic abnormalities related to the attachment state occur, the abnormality occurrence interval is usually not constant but is either N or N+1. N is an integer value in the result (quotient) obtained by dividing the circumferential length of the roll by the width of the intended sheet portion. If two different values, such as N or N+1, appear as the abnormality occurrence interval, the accuracy of determining whether or not a periodic abnormality exists may be reduced. The relationship between the ratio of the remainder of the result (quotient) obtained by dividing the circumferential length of the roll by the width of the intended sheet portion to the width of the intended sheet portion and the probability that the abnormality occurrence interval will be N or N+1 is shown in Figure 16.

[0026] In this regard, when the abnormality occurrence interval at which the derived frequency is greatest is taken as the reference interval, if the derived frequency in the abnormality occurrence interval obtained by subtracting 1 from the reference interval (hereinafter sometimes referred to as the "-1 interval") is greater than the derived frequency in the abnormality occurrence interval obtained by adding 1 to the reference interval (hereinafter sometimes referred to as the "+1 interval"), as shown in Fig. 17, it can be said that the "-1 interval" is N and the reference interval is N+1. On the other hand, if the derived frequency in the "-1 interval" is smaller than the derived frequency in the "+1 interval", as shown in Fig. 18, it can be said that the reference interval is N and the "+1 interval" is N+1.

[0027] Therefore, when the reference interval is N+1, the derived frequency at the reference interval is based on the value obtained by adding the derived frequency at the abnormality occurrence interval N, and when the reference interval is N, the derived frequency is based on the value obtained by adding the derived frequency at the reference interval to the derived frequency at the abnormality occurrence interval N+1. This makes it possible to prevent a decrease in judgment accuracy that occurs when two different numerical values, N or N+1, are generated as the abnormality occurrence interval.

[0028] Based on this, according to the above-mentioned means 3, the periodic abnormality determination means compares the derived frequency in an abnormality occurrence interval obtained by subtracting 1 from the reference interval ("-1 interval") with the derived frequency in an abnormality occurrence interval obtained by adding 1 to the reference interval ("+1 interval"), and determines whether or not a periodic abnormality exists based on the value obtained by adding the larger of these two derived frequencies to the derived frequency in the reference interval. Therefore, while using the number of sheets of the expected sheet portions as the abnormality occurrence interval, it is possible to suppress problems caused by using the expected sheet portions, and ultimately to more accurately determine whether or not a periodic abnormality exists. As a result, it is possible to more accurately detect whether or not an abnormality exists in the sealing means.

[0029] Means 4. The attachment state detection means is configured to use a predetermined first threshold value to detect a severely abnormal portion where the attachment state of the cover film to the container film is poor, and to use a second threshold value different from the first threshold value to detect a mildly abnormal portion where the attachment state is milder than the severely abnormal portion, The sealing means abnormality detection system described in means 1, characterized in that the sealing abnormality portion includes the severe abnormality portion and the mild abnormality portion.

[0030] In a configuration that detects only severely abnormal sealing portions (for example, abnormal portions at a level that would cause the final blister sheet to be judged as a defective product), foreign matter may adhere to the sealing means, and although abnormal sealing portions would normally be detected periodically, it is relatively easy for some circumstances (for example, the abnormality becoming minor by chance) to cause some of the abnormal sealing portions to not be properly detected.

[0031] In this regard, according to the above-mentioned method 4, the abnormal sealing portion includes a severely abnormal portion detected using the first threshold value and a mildly abnormal portion detected using a second threshold value different from the first threshold value, which is an abnormal portion less severe than the severely abnormal portion (for example, an abnormal portion at a level that would allow the final blister sheet to be determined as a non-defective product). Therefore, it is possible to more effectively prevent the occurrence of a situation in which some of the abnormal sealing portions go undetected. This makes it possible to more accurately determine the presence or absence of periodic abnormalities, and ultimately to more accurately detect the presence or absence of abnormalities in the sealing means.

[0032] Furthermore, according to the above-mentioned method 4, an abnormality in the sealing means can be detected at a stage where most of the sealing abnormalities are minor. Therefore, appropriate measures such as cleaning the sealing means can be taken before major abnormalities occur periodically (i.e., before defective blister sheets periodically occur). This allows for improved productivity and reduced costs in the manufacture of blister sheets.

[0033] Means 5. The frequency acquisition means is configured to derive the abnormality occurrence interval and acquire the derived frequency for each of a plurality of regions obtained by dividing the blister film in its width direction, The sealing means abnormality detection system described in means 1, characterized in that the periodic abnormality determination means determines whether or not there is a periodic abnormality based on the derived frequency for each of the multiple regions.

[0034] When defective seals occur periodically, they usually occur only in specific regions among the multiple regions obtained by dividing the blister film in the width direction. On the other hand, when defective seals occur due to, for example, foreign matter adhering to the container film rather than the sealing means, that is, when defective seals occur suddenly, the defective seals are not ubiquitous in specific regions but can occur in any region.

[0035] In consideration of this, according to the above-mentioned means 5, the periodic abnormality determination means determines the presence or absence of periodic abnormalities based on the derived frequencies for each of the multiple regions. Therefore, when determining the presence or absence of periodic abnormalities, the influence of suddenly occurring sealing abnormalities can be reduced. As a result, the accuracy of determining the presence or absence of periodic abnormalities can be further improved.

[0036] Means 6. A blister packaging machine equipped with the sealing means abnormality detection system according to Means 1.

[0037] According to the sixth means, the same effects as those of the first means can be achieved.

[0038] The technical features of the above means may be combined as appropriate. For example, the technical features of the above means 2 or 3 may be combined with the technical features of the above means 4. Furthermore, the technical features of the above means 4 may be combined with the technical features of the above means 5. [Brief explanation of the drawings]

[0039] [Figure 1] FIG. 1 is a perspective view of a PTP sheet. [Figure 2] FIG. 1 is a partially enlarged cross-sectional view of a PTP sheet. [Figure 3] FIG. 1 is a perspective view of a PTP film. [Figure 4] FIG. 2 is a perspective view showing a schematic configuration of a heating roll. [Figure 5] FIG. 1 is a schematic diagram of a PTP packaging machine. [Figure 6] 2 is a block diagram showing the functional configuration of the sealing device abnormality detection system. FIG. [Figure 7] 10 is a flowchart showing the flow of an inspection process. [Figure 8] 10 is an explanatory diagram for explaining the inspection results stored in association with the sheet number when a severely abnormal part or a mildly abnormal part is detected. FIG. [Figure 9] 10A and 10B are explanatory diagrams for explaining an example of an abnormality occurrence interval derived from inspection results and a derived frequency acquired from the abnormality occurrence interval; [Figure 10] 10A and 10B are explanatory diagrams for explaining an example of an abnormality occurrence interval derived from inspection results and a derived frequency acquired from the abnormality occurrence interval; [Figure 11] 10A and 10B are explanatory diagrams for explaining an example of an abnormality occurrence interval derived from inspection results and a derived frequency acquired from the abnormality occurrence interval; [Figure 12] FIG. 10 is a graph illustrating acquisition of a correction frequency. [Figure 13] 10 is a flowchart showing a flow of a sealing device abnormality determination process. [Figure 14] FIG. 2 is a schematic plan view of a PTP film in another embodiment, showing a plurality of regions formed by dividing the PTP film in the width direction. [Figure 15] FIG. 10 is an explanatory diagram for explaining an example of an inspection result for each region and a derivation frequency in each region in another embodiment. [Figure 16] FIG. 10 is a table showing the relationship between the ratio of the remainder obtained by dividing the circumferential length of the roll by the width of the portion intended for the sheet to the width of the portion intended for the sheet, and the probability that the abnormality occurrence interval will be N or N+1. [Figure 17] FIG. 10 is a graph showing an example of the derived frequency when the "-1 interval" is N and the reference interval is N+1. [Figure 18] FIG. 10 is a graph showing an example of the derived frequency when the reference interval is N and the "+1 interval" is N+1. DETAILED DESCRIPTION OF THE INVENTION

[0040] Hereinafter, an embodiment will be described with reference to the drawings. First, the structure of a PTP sheet as a "blister sheet" will be described in detail.

[0041] As shown in FIGS. 1 and 2, the PTP sheet 1 has a container film 3 with a plurality of pocket portions 2, and a cover film 4 attached to the container film 3 so as to cover the pocket portions 2.

[0042] The container film 3 is made of transparent or translucent polypropylene (PP) or polyvinyl chloride (PVC) and has light transmittance.

[0043] On the other hand, the cover film 4 is made of thin (e.g., about 15 to 20 μm) aluminum (aluminum foil) with a sealant made of, for example, a predetermined resin applied to the surface and a predetermined resin layer provided on the back surface (the surface opposite to the container film 3). The materials of the container film 3 and the cover film 4 may be changed as appropriate.

[0044] Furthermore, parallelogram-shaped mesh seals 4a are formed on the cover film 4. The seals 4a form a plurality of identically shaped parallelogram portions Q. Of course, the parallelogram portions Q may be not only parallelogram-shaped but also square, rectangular, or diamond-shaped.

[0045] The PTP sheet 1 is formed in a rectangular shape in plan view with four arc-shaped corners. The PTP sheet 1 has two rows of pockets formed in the short side direction, each row consisting of three pockets 2 arranged along the long side direction. In other words, a total of six pockets 2 are formed. Each pocket 2 contains one tablet 5 as the "contents."

[0046] The PTP sheet 1 is produced by punching out a strip-shaped PTP film 6 (see FIG. 3) formed from a strip-shaped container film 3 and a strip-shaped cover film 4 into a sheet. In this embodiment, the PTP film 6 corresponds to a "blister film." The PTP film 6 is configured such that pre-sheet portions 101, which are portions that will become the PTP sheet 1 when punched by a sheet punching device 37 described below, are aligned along the longitudinal direction of the PTP film 6, and one row of the pre-sheet portions 101 is provided.

[0047] Next, we will explain the general configuration of a PTP packaging machine 10 for manufacturing the PTP sheet 1. In this embodiment, the PTP packaging machine 10 corresponds to a "blister packaging machine."

[0048] As shown in Fig. 5, a raw web of strip-shaped container film 3 is wound into a roll on the most upstream side of the PTP packaging machine 10. The pull-out end of the rolled container film 3 is guided by a guide roll 13. The container film 3 is wrapped around an intermittent feed roll 14 on the downstream side of the guide roll 13. The intermittent feed roll 14 is connected to an intermittently rotating motor and feeds the container film 3 intermittently.

[0049] Between the guide roll 13 and the intermittent feed roll 14, a heating device 15 and a pocket forming device 16 are arranged in this order along the transport path of the container film 3. Then, after the container film 3 has been heated by the heating device 15 and has become relatively flexible, the pocket forming device 16 forms multiple pockets 2 at predetermined positions in the container film 3. The pockets 2 are formed during the intervals between the transport operations of the container film 3 by the intermittent feed roll 14.

[0050] The container film 3 fed from the intermittent feed roll 14 is wrapped around a tension roll 18, a guide roll 19, and a film receiving roll 20, in that order. The film receiving roll 20 is connected to a motor that rotates at a constant speed, so it transports the container film 3 continuously at a constant speed. The tension roll 18 pulls the container film 3 toward the tension side by its elastic force, preventing slack in the container film 3 due to differences in the transport operations of the intermittent feed roll 14 and the film receiving roll 20, and keeping the container film 3 in a constantly tensed state.

[0051] A filling device 21 is disposed between the guide roll 19 and the film receiving roll 20 along the conveying path of the container film 3. In this embodiment, the filling device 21 constitutes the "filling means." The filling device 21 is equipped with a cylindrical chute that stores the tablets 5 in a line and a shutter (both not shown) that can open and close the outlet of the chute, and fills the tablets 5 into the pocket portion 2 by opening the shutter at a predetermined timing. The filling device 21 may also be equipped with an adsorption drum (not shown) that can adsorb the tablets 5, and fill the tablets 5 into the pocket portion 2 by releasing the adsorption.

[0052] On the other hand, the original web of the cover film 4 formed in a strip shape is wound into a roll on the most upstream side. The leading end of the rolled cover film 4 is guided toward the heating roll 24 by a guide roll 23.

[0053] The heating roll 24 can be pressed against the film receiving roll 20, and the container film 3 and the cover film 4 are fed between the two rolls 20, 24. Then, as the container film 3 and the cover film 4 pass between the two rolls 20, 24 in a heated and pressed state, the cover film 4 is attached to the container film 3, and the pocket portions 2 are closed with the cover film 4. In this manner, a strip-shaped PTP film 6 is produced in which tablets 5 are housed in each pocket portion 2. In this embodiment, the film receiving roll 20 and the heating roll 24 constitute a sealing device 25 as a "sealing means," and the two rolls 20, 24 constitute "two rolls."

[0054] Furthermore, a plurality of protrusions 24a (see FIG. 4) having a triangular cross section are provided on at least the portion of the outer periphery of the heating roll 24 that faces the cover film 4 passing between the rolls 20, 24. In this embodiment, the protrusions 24a are arranged to form a parallelogram (square in this embodiment) mesh. The protrusions 24a bite into the cover film 4 and the container film 3, forming the seals 4a in the PTP film 6, and as a result, the cover film 4 is firmly attached to the container film 3.

[0055] As the production of the PTP sheet 1 continues, foreign matter (such as the resin that makes up the cover film 4) may get into the recess surrounded by the protrusions 24a, causing the protrusions 24a to not fully penetrate the cover film 4, etc., and preventing the seals 4a from being formed. Therefore, to ensure that the seals 4a are formed reliably, it is necessary to take measures such as cleaning the sealing device 25 (especially the heating roll 24) as needed.

[0056] The PTP film 6 sent out from the film receiving roll 20 is wrapped around a guide roll 26, a tension roll 27, and an intermittent feed roll 28, in that order. The intermittent feed roll 28 is connected to an intermittently rotating motor, and therefore intermittently transports the PTP film 6. The tension roll 27 pulls the PTP film 6 toward the tension side by its elastic force, preventing slack in the PTP film 6 due to differences in the transport operations of the film receiving roll 20 and the intermittent feed roll 28, and maintaining the PTP film 6 in a constantly tensed state.

[0057] A post-sealing inspection device 60 is provided along the transport path of the PTP film 6 between the film receiving roll 20 and the tension roll 27. In this embodiment, the post-sealing inspection device 60 constitutes the "attachment state inspection means." The post-sealing inspection device 60 is a component of the sealing device abnormality detection system 50, which will be described later. A more detailed configuration of the sealing device abnormality detection system 50, which includes the post-sealing inspection device 60, will be described later.

[0058] The PTP film 6 fed from the intermittent feed roll 28 is wrapped around a tension roll 31 and an intermittent feed roll 32 in that order. The intermittent feed roll 32 is connected to an intermittently rotating motor, and therefore intermittently transports the PTP film 6. The tension roll 31 is in a state where it pulls the PTP film 6 toward the tension side by its elastic force, preventing slack in the PTP film 6 between the intermittent feed rolls 28 and 32.

[0059] Between the intermittent feed roll 28 and the tension roll 31, a slit forming device 33 and an imprinting device 34 are disposed in this order along the transport path of the PTP film 6. The slit forming device 33 has the function of forming a separation slit at a predetermined position in the PTP film 6. The imprinting device 34 has the function of imprinting an imprint at a predetermined position on the PTP film 6. Note that the separation slit and imprinting are not shown in Figure 1 etc.

[0060] The PTP film 6 fed from the intermittent feed roll 32 is wrapped around a tension roll 35 and a continuous feed roll 36 in that order downstream. A sheet punching device 37 is disposed between the intermittent feed roll 32 and the tension roll 35 along the transport path of the PTP film 6. The sheet punching device 37 has the function of punching out the outer edge of the PTP film 6 into individual PTP sheets, that is, the function of separating the PTP sheets 1 from the PTP film 6. In this embodiment, the sheet punching device 37 constitutes the "separating means."

[0061] The PTP sheets 1 obtained by the sheet punching device 37 are transported by a conveyor 39 and temporarily stored in a finished product hopper 40. However, if the PTP sheets 1 are determined to be defective by the post-sealing inspection device 60, the PTP sheets 1 determined to be defective are not sent to the finished product hopper 40 but are separately discharged by a defective sheet discharge mechanism 41.

[0062] The defective sheet discharge mechanism 41 is configured to be able to acquire the inspection results from the post-seal inspection device 60, and uses these inspection results to discharge defective PTP sheets 1 in which the cover film 4 is abnormally attached to the container film 3. The defective sheet discharge mechanism 41 is also configured to be able to grasp the correspondence between the PTP sheets 1 being transported by the conveyor 39 and the sheet numbers described below, and uses this correspondence to identify the PTP sheets 1 to be discharged.

[0063] A cutting device 42 is disposed downstream of the continuous feed roll 36. An unnecessary film portion 43, which constitutes a strip-shaped residual material portion (scrap portion) remaining after punching by the sheet punching device 37, is guided by the tension roll 35 and the continuous feed roll 36, and then led to the cutting device 42. The cutting device 42 cuts the unnecessary film portion 43 to a predetermined size. The cut unnecessary film portion 43 (scrap) is stored in a scrap hopper 44 and then disposed of separately.

[0064] Next, the sealing device abnormality detection system 50 will be described. In this embodiment, the sealing device abnormality detection system 50 constitutes a "sealing means abnormality detection system." The sealing device abnormality detection system 50 is intended to detect abnormalities in the sealing device 25 involved in attaching the cover film 4 to the container film 3. As shown in FIGS. 5 and 6, the sealing device abnormality detection system 50 includes a post-sealing inspection device 60 and an abnormality detection processing device 70.

[0065] The post-sealing inspection device 60 is a reflected light type inspection device that inspects the protruding portion side of the pocket portion 2 in the PTP film 6 after sealing, and inspects for the inspection item of "non-sealing wrinkles." "Non-sealing wrinkles" is an inspection item that checks whether the cover film 4 is properly attached to the container film 3, that is, whether the seal is good or bad. The post-sealing inspection device 60 is equipped with a lighting device 61, a camera 62, and an image processing device 63.

[0066] The lighting device 61 is disposed on the protruding portion side of the pocket portion 2 in the PTP film 6, and irradiates the PTP film 6 with predetermined light (for example, near-infrared light). More specifically, the lighting device 61 has a light source 61a for irradiating the cover film 4 with predetermined light through the container film 3, a parallel light filter 61b for transmitting mainly parallel light, and a half mirror 61c for near-infrared light. The light irradiated from the light source 61a is reflected by the half mirror 61c and irradiated onto the PTP film 6 from approximately the same direction as the imaging direction (optical axis direction) of the camera 62. In other words, the lighting device 61 is capable of coaxial illumination with the camera 62.

[0067] The camera 62, like the lighting device 61, is arranged on the protruding portion side of the pocket portion 2 in the PTP film 6. As the camera 62, a CCD camera, CMOS camera, or the like having sensitivity in the wavelength region of the light irradiated from the lighting device 61 can be used. The camera 62 takes two-dimensional images of the light irradiated from the lighting device 61 and reflected from the cover film 4, etc. The image data (luminance image data) obtained by imaging by the camera 62 is converted into a digital signal inside the camera 62 and then input in the form of a digital signal to the image processing device 63.

[0068] In the acquired image data, the brightness (luminance) of the seal 4a is usually low, and the brightness of the parallelogram portion Q surrounded by the seal 4a is high. Also, if there is a portion of the PTP film 6 where the seal 4a is not formed (non-seal portion) and there is an abnormality in the attachment of the cover film 4 to the container film 3, the non-seal portion in the image data will have high brightness, just like the parallelogram portion Q.

[0069] The image processing device 63 is composed of a computer system 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, and is capable of executing various processes such as image processing.

[0070] The image processing device 63 is equipped with an image memory 631, an inspection result storage device 632, a judgment memory 633, a camera timing control device 634, and a CPU and input / output interface 635, and is capable of performing various image processing such as binarization processing and block processing, various judgment processing, etc.

[0071] The image memory 631 stores image data output from the camera 62. Inspection is carried out based on the image data stored in this image memory 631. Of course, when carrying out the inspection, processing may be carried out on the image data. For example, processing such as masking processing or shading correction may be carried out. Note that binarized image data obtained by performing binarization processing on image data, masked image data obtained by performing masking processing, etc. may also be stored in the image memory 631.

[0072] The inspection result storage device 632 stores data such as coordinates related to the image data, inspection result data, statistical data obtained by stochastically processing the inspection result data, etc. The inspection result data stored in the inspection result storage device 632 is output to the defective sheet discharge mechanism 41.

[0073] Furthermore, the inspection result storage device 632 stores the sheet number for identifying the PTP sheet 1 (intent of sheet 101) in association with the inspection results (detection results) from the inspection process described below (see FIG. 8, etc.). The sheet number is an integer equal to or greater than 0, such as 0, 1, 2, or 3, and increases by one in the order in which the PTP sheet 1 is manufactured. Furthermore, the sheet number is set for each intent of sheet 101, and ultimately functions as information for individually identifying the PTP sheet 1 obtained. Note that in FIG. 8, the spacing between the seal stitches 4a and the sizes of the severely abnormal portion JI and the mildly abnormal portion KI, which will be described later, are shown at a significantly larger scale than the actual spacing and size.

[0074] The judgment memory 633 stores judgment values ​​(such as thresholds) used in the inspection. The judgment values ​​used in the inspection include, for example, the dimensions of the PTP sheet 1, pocket portion 2, tablet 5, etc., the shapes and dimensions of various window frames for defining various inspection areas, thresholds related to binarization processing, thresholds related to area judgment, etc.

[0075] The thresholds for determining the area include a first threshold P1 and a second threshold P2, which is a different value from the first threshold P1 and, in this embodiment, is a smaller value than the first threshold P1. The first threshold P1 is used to detect the presence or absence of a severely abnormal portion JI (see FIG. 8), which is a portion where the attachment state of the cover film 4 to the container film 3 is poor. The second threshold P2 is used to detect the presence or absence of a mildly abnormal portion KI (see FIG. 8), which is a portion where the abnormality is less severe than the severely abnormal portion.

[0076] The camera timing control device 634 controls the timing of capturing images by the camera 62. The timing of capturing images by the camera 62 is controlled based on a signal from an encoder (not shown) provided in the PTP packaging machine 10, and an image is captured by the camera 62 every time a predetermined amount of PTP film 6 is fed.

[0077] The CPU and input / output interface 635 are responsible for various controls in the post-sealing inspection device 60. For example, it executes various processing programs using the stored contents of the judgment memory 633, and has the function of sending and receiving various signals to and from the constituent devices of the PTP packaging machine 10. This allows the defective sheet discharge mechanism 41 to discharge defective products, etc.

[0078] Next, the inspection process performed by the post-sealing inspection device 60 will be described with reference to the flowchart of Fig. 7. This inspection process is executed for each of the intended sheet portions 101 by the CPU and the input / output interface 635.

[0079] In the inspection process, first, in step S11, a masking process is performed on the image data captured by the camera 62 and stored in the image memory 631. More specifically, using preset masking data, a masking process is performed on the area within the pocket portion 2 (pocket portion area) where the container film 3 and the cover film 4 are not attached, and the sheet portion area outside the pocket portion 2 is set as the area to be inspected. The masked image data after the masking process is stored in the image memory 631.

[0080] In step S12, a "brightness determination process" is performed on the masked image data stored in the image memory 631. This brightness determination process is performed using an inspection frame and is similar to the process described in Japanese Patent Application Laid-Open No. 2006-84228, so a detailed description thereof will be omitted.

[0081] In step S13, based on the brightness determination result in step S12, a binarization process is performed on the masking image data stored in the image memory 631. As a result, binarized image data is formed in which the seal stitches 4a become "0 (dark)" and the parallelogram portion Q and non-seal portions become "1 (light)". The binarized image data is stored in the image memory 631.

[0082] In step S14, color inversion (negative-positive inversion) is performed on the binary image data stored in the image memory 631, and then block processing is performed. Block processing includes a process of identifying each connected component for "0" (dark) in the binary image data, and a labeling process of labeling each connected component. Block processing basically extracts blocks corresponding to parallelogram portions Q. Furthermore, if there are non-seal portions, relatively large blocks formed by connecting adjacent parallelogram portions Q are extracted.

[0083] In the next step S15, the area Sy of each connected component identified in step S14 is calculated. The area Sy is expressed, for example, in terms of the number of dots.

[0084] Next, in step S16, the area Sy of each connected component is compared with the first threshold value P1 stored in the judgment memory 633. If the area Sy of the connected component is greater than the first threshold value P1 (step S16: YES), then in step S17, the connected component (clump) is detected as a severely abnormal portion JI (the portion marked with a scattered dot pattern on the left side in FIG. 8). The severely abnormal portion JI has a fairly large area, and is a portion that should be judged to be defective in terms of the state of attachment of the cover film 4 to the container film 3. In other words, the severely abnormal portion JI is an abnormal portion at a level that would cause the pre-sheet portion 101 or the PTP sheet 1 obtained from the pre-sheet portion 101 to be judged to be a defective product.

[0085] Then, in step S18, the inspected intended sheet portion 101 is determined to be defective. Also, in step S19, a severely abnormal portion JI is detected in association with the sheet number, and the inspection result (detection result) that the sheet is determined to be defective is stored in the inspection result storage device 632. In this embodiment, the inspection result when a severely abnormal portion JI is detected and the sheet is determined to be defective is represented by "x" (see FIG. 8, etc.).

[0086] On the other hand, if the area Sy of each connected component is equal to or smaller than the first threshold P1 (step S16: NO), the area Sy of each connected component is compared with the second threshold P2 stored in the determination memory 633 in step S20.

[0087] If the area Sy of the connected component is greater than the second threshold value P2 (step S20: YES), then in step S21, the connected component (clump) is detected as a mildly abnormal portion KI (the portion marked with a scattered dot pattern on the right side in FIG. 8). The mildly abnormal portion KI has an area slightly larger than the area of ​​the parallelogram portion Q, and is a portion that is judged to be generally good despite having a slight abnormality in the state of attachment of the cover film 4 to the container film 3. In other words, the mildly abnormal portion KI is an abnormal portion at a level that would not cause any problems in judging the pre-sheet portion 101 or the PTP sheet 1 obtained from the pre-sheet portion 101 as a non-defective product. The mildly abnormal portion KI and the severely abnormal portion JI are each included in the sealing abnormal portion SI, which is a portion where there is an abnormality in the state of attachment of the cover film 4 to the container film 3.

[0088] Then, in step S22, the inspected prospective sheet portion 101 is determined to be a non-defective product. Also, in step S19, a slight abnormality portion KI is detected in association with the sheet number, and the inspection result that the sheet is determined to be a non-defective product is stored in the inspection result storage device 632. In this embodiment, the inspection result in which a slight abnormality portion KI is detected and the sheet is determined to be a non-defective product is represented by "△" (see FIG. 8, etc.).

[0089] On the other hand, if the area Sy of each connected component is equal to or less than the second threshold value P2 (step S20: NO), the inspected intended sheet portion 101 is determined to be a non-defective product in step S22, and the inspection result indicating a non-defective product is stored in association with the sheet number in the inspection result storage device 632 in step S19. In this embodiment, the inspection result in the case where no abnormal seal portion SI (severely abnormal portion JI or slightly abnormal portion KI) is detected and the product is determined to be a non-defective product is represented by "◯" (see FIG. 8, etc.).

[0090] According to the post-sealing inspection device 60, the presence or absence of sealing abnormalities SI (severely abnormalities JI and slightly abnormalities KI) is detected for each sheet-intent portion 101 (PTP sheet 1), and the sheet number for identifying the sheet-intent portion 101 is associated with information regarding the presence or absence of sealing abnormalities SI, and the information is then stored in the inspection result memory device 632.

[0091] Next, we will explain the abnormality detection processing device 70. The abnormality detection processing device 70 is a device for detecting abnormalities in the sealing device 25 related to the attachment of the cover film 4 to the container film 3 based on the inspection results by the post-sealing inspection device 60.

[0092] Like the image processing device 63, the abnormality detection processing device 70 is configured by a computer system equipped with a CPU, ROM, RAM, etc., and is capable of executing various processes such as image processing. As shown in Figures 5 and 6, the abnormality detection processing device 70 includes a frequency acquisition unit 71, a periodic abnormality determination unit 72, a sealing device abnormality determination unit 73, and an abnormality notification unit 74. In this embodiment, the frequency acquisition unit 71 constitutes the "frequency acquisition means," and similarly, the periodic abnormality determination unit 72 constitutes the "periodic abnormality determination means," and the sealing device abnormality determination unit 73 constitutes the "sealing means abnormality determination means." The functions of the frequency acquisition unit 71 and the like are realized by cooperation between various hardware components such as the CPU, ROM, and RAM, and predetermined software.

[0093] The frequency acquisition unit 71 derives an abnormality occurrence interval L that correlates with the distance along the longitudinal direction of the PTP film 6 from an abnormal sealing portion SI (severe abnormality portion JI or mild abnormality portion KI) detected by the post-sealing inspection device 60 to the next abnormal sealing portion SI detected by the post-sealing inspection device 60 after the abnormal sealing portion SI. More specifically, each time the PTP film 6 is transported by a predetermined length HK (see FIG. 9, etc.), the frequency acquisition unit 71 derives the abnormality occurrence interval L related to the abnormal sealing portion SI present in the PTP film 6 of the predetermined length HK.

[0094] Here, the frequency acquisition unit 71 derives the "number of sheets 101" corresponding to the interval from the abnormal sealing portion SI detected by the post-sealing inspection device 60 to the next abnormal sealing portion SI detected by the post-sealing inspection device 60 as the abnormality occurrence interval L.

[0095] Therefore, for example, if an abnormal sealing portion SI (serious abnormal portion JI) is detected in each of the pre-planed sheet portion 101 identified by sheet number "0" and the pre-planed sheet portion 101 identified by sheet number "6," the frequency acquisition unit 71 derives "6" (sheets) as the abnormality occurrence interval L (see FIGS. 9 and 10). Also, for example, if a minor abnormality portion KI is detected in the pre-planed sheet portion 101 identified by sheet number "18" and a serious abnormality portion JI is detected in the pre-planed sheet portion 101 identified by sheet number "24," the frequency acquisition unit 71 derives "6" as the abnormality occurrence interval L (see FIGS. 9 and 10). Note that FIGS. 9 and 10 assume a state in which the width W (see FIG. 8) of the pre-planed sheet portion 101 is an integer multiple of the circumferential length of the heating roll 24, but this state rarely occurs.

[0096] Furthermore, in addition to the periodic sealing abnormality portions SI caused by the sealing device 25, sudden sealing abnormality portions SI may also occur, and the frequency acquisition unit 71 uses such sudden sealing abnormality portions SI to derive the abnormality occurrence interval L. Therefore, for example, in the example shown in Fig. 10, the sealing abnormality portion SI of the expected sheet portion 101 identified by sheet number "13" is estimated to be sudden, but the frequency acquisition unit 71 derives "5" as the abnormality occurrence interval L because an abnormal sealing portion SI (a serious abnormality portion JI or a minor abnormality portion KI) has been detected in each of the expected sheet portions 101 identified by sheet number "13" or "18."

[0097] Even when only periodic sealing abnormalities SI caused by the sealing device 25 occur, if the width W of the pre-sealing portion 101 is not an integer multiple of the circumferential length of the heating roll 24, the abnormality occurrence interval L is not constant but is N or N+1. N is an integer value in the result (quotient) obtained by dividing the circumferential length of the heating roll 24 by the width W of the pre-sealing portion 101. Therefore, when the width W of the pre-sealing portion 101 is not an integer multiple of the circumferential length of the heating roll 24 and periodic sealing abnormalities SI occur, the abnormality occurrence interval L will be one of two types, for example, "6" or "7" (see FIG. 11).

[0098] Furthermore, the frequency acquisition unit 71 temporarily stores the derived abnormality occurrence interval L and acquires the derived frequency of the abnormality occurrence interval L for each abnormality occurrence interval L. In this embodiment, the total derived frequency of the abnormality occurrence interval L is acquired as the derived frequency. Therefore, if the number of times the abnormality occurrence interval L has become "6" is "5," the frequency acquisition unit 71 acquires "5" as the derived frequency corresponding to L=6 (see FIG. 9). Also, if the number of times the abnormality occurrence interval L has become "6" is "3," and the number of times the abnormality occurrence interval L has become "1," "2," "4," or "5" is "1," respectively, the frequency acquisition unit 71 acquires "3" as the derived frequency corresponding to L=6 and "1" as the derived frequency corresponding to L=1, 2, 4, or 5 (see FIG. 10).

[0099] The periodic abnormality determination unit 72 determines the presence or absence of a periodic abnormality related to the attachment state of the cover film 4 to the container film 3 based on the derived frequency acquired by the frequency acquisition unit 71. Specifically, the periodic abnormality determination unit 72 first sets the abnormality occurrence interval at which the derived frequency is maximum as a reference interval, and compares the derived frequency at an abnormality occurrence interval obtained by subtracting 1 from the reference interval (hereinafter sometimes referred to as a "-1 interval") with the derived frequency at an abnormality occurrence interval obtained by adding 1 to the reference interval (hereinafter sometimes referred to as a "+1 interval"). For example, in the example shown in FIG. 11, the abnormality occurrence interval L (reference interval) at which the derived frequency is maximum is "6," so the derived frequency at L=5 is compared with the derived frequency at L=7.

[0100] Then, the periodic abnormality determination unit 72 obtains a value (corrected frequency) by adding the larger of these two derived frequencies to the derived frequency at the reference interval. For example, in the example shown in Fig. 11, the derived frequency at L = 7 (= 1) is greater than the derived frequency at L = 5 (= 0), so the corrected frequency is obtained by adding the derived frequency at L = 7 (= 1) to the derived frequency at the reference interval (= 4) [= 5 (= 4 + 1)] (see Fig. 12).

[0101] If the number of derived frequencies in the "-1 interval" and the "+1 interval" is the same, the corrected frequency can be obtained by adding one of these derived frequencies to the derived frequency in the reference interval.

[0102] Furthermore, the periodic abnormality determination unit 72 determines whether or not there is a periodic abnormality by comparing the correction frequency with a preset threshold value X1 (hereinafter referred to as "periodic abnormality determination threshold value") for determining whether or not there is a periodic abnormality related to the attachment state of the cover film 4 to the container film 3. In this embodiment, the periodic abnormality determination unit 72 determines that there is a periodic abnormality when the correction frequency is greater than the periodic abnormality determination value X1, and determines that there is no periodic abnormality when the correction frequency is equal to or less than the periodic abnormality determination threshold value X1.

[0103] The sealing device abnormality determination unit 73 determines whether or not there is an abnormality in the sealing device 25 involved in attaching the cover film 4 to the container film 3, based on the determination result by the periodic abnormality determination unit 72. More specifically, if the periodic abnormality determination unit 72 determines that there is a periodic abnormality, the sealing device abnormality determination unit 73 determines that there is an abnormality in the sealing device 25. On the other hand, if the periodic abnormality determination unit 72 determines that there is no periodic abnormality, the sealing device abnormality determination unit 73 determines that the sealing device 25 is normal.

[0104] When the sealing device abnormality determination unit 73 determines that there is an abnormality in the sealing device 25, the abnormality notification unit 74 performs a predetermined notification process to notify the outside that there is an abnormality in the sealing device 25. The abnormality notification unit 74 notifies the outside that there is an abnormality in the sealing device 25, for example, by displaying predetermined warning information on a display device (e.g., a liquid crystal display, etc.) or by generating a predetermined warning sound from an audio device (e.g., a speaker, etc.). By notifying the outside of the abnormality in the sealing device 25, measures such as cleaning of the sealing device 25 can be taken more reliably and earlier.

[0105] Next, the sealing device abnormality determination process for detecting whether or not there is an abnormality in the sealing device 25, which is performed by the abnormality detection processing device 70, will be described with reference to the flowchart of FIG.

[0106] In the sealing device abnormality determination process, first, in step S31, it is determined whether the PTP film 6 has been conveyed a predetermined length HK since the end of the previous sealing device abnormality determination process. In other words, it is determined whether the timing has come to determine whether there is an abnormality in the sealing device 25. The conveyance amount of the PTP film 6 can be determined based on a signal from an encoder (not shown) provided in the PTP packaging machine 10. Note that the length HK corresponds to a number of sheets (e.g., 35 sheets) of the intended sheet portion 101 (see FIG. 9, etc.).

[0107] The processing of step S31 is repeated until the PTP film 6 has been transported by the length HK, and when the PTP film 6 has been transported by the length HK (step S31: YES), in steps S32 and S33, the frequency acquisition unit 71 derives the abnormality occurrence interval L and acquires the derived frequency.

[0108] In the following step S34, the periodic abnormality determination unit 72 determines whether the derived frequency in the abnormality occurrence interval obtained by subtracting 1 from the reference interval ("-1 interval") is greater than the derived frequency in the abnormality occurrence interval obtained by adding 1 to the reference interval ("+1 interval").

[0109] If the derived frequency in the "-1 interval" is greater than the derived frequency in the "+1 interval" (step S34: YES), in step S35, the periodic abnormality determination unit 72 obtains a corrected frequency H1 obtained by adding the derived frequency in the "-1 interval" to the derived frequency in the reference interval.

[0110] On the other hand, if the derived frequency in the "-1 interval" is less than or equal to the derived frequency in the "+1 interval" (step S34: NO), in step S36, the periodic abnormality determination unit 72 obtains a corrected frequency H2 obtained by adding the derived frequency in the "+1 interval" to the derived frequency in the reference interval.

[0111] In step S37 following steps S35 and S36, it is determined whether the correction frequency H1 or the correction frequency H2 acquired in step S35 or step S36 is greater than the period abnormality determination threshold value X1.

[0112] If the correction frequency H1 or the correction frequency H2 is greater than the periodic abnormality determination threshold value X1 (step S37: YES), in step S38, the sealing device abnormality determination unit 73 determines that there is an abnormality in the sealing device 25. Then, in step S39, the abnormality notification unit 74 notifies the outside that there is an abnormality in the sealing device 25.

[0113] On the other hand, if the correction frequency H1 or the correction frequency H2 is less than or equal to the periodic abnormality determination threshold value X1 (step S37: NO), in step S40, the sealing device abnormality determination unit 73 determines that there is no abnormality in the sealing device 25 (the sealing device 25 is normal).

[0114] As described above in detail, according to this embodiment, by utilizing the abnormality occurrence interval L and the derived frequency, it is possible to accurately determine the presence or absence of periodic abnormalities related to the attachment state of the cover film 4 to the container film 3. As a result, it is possible to more easily and accurately determine the presence or absence of abnormalities in the sealing device 25.

[0115] Furthermore, the presence or absence of an abnormality in the sealing device 25 can be determined using only the inspection results (detection results) from the post-sealing inspection device 60. In other words, there is no need to provide two or more inspection devices to determine the presence or absence of an abnormality in the sealing device 25; only one inspection device is sufficient. This makes it possible to more reliably prevent the system from becoming complicated, and to reduce costs associated with the manufacturing and maintenance of the system.

[0116] In addition, the frequency acquisition unit 71 derives the "number of sheets 101" corresponding to the distance from one abnormal sealing portion SI to the next abnormal sealing portion SI as the abnormality occurrence interval L. Therefore, the abnormality occurrence interval L can be derived without using the circumferential length of the heating roll 24, and an increase in the workload can be more reliably prevented.

[0117] Furthermore, since the abnormal seal portion SI can be detected for each intended sheet portion 101, it is possible to easily obtain the number of intended sheet portions 101 as the abnormality occurrence interval L. This reduces the processing load when obtaining the abnormality occurrence interval L.

[0118] Furthermore, since the abnormal seal portion SI can be detected for each PTP sheet 1, it becomes easier to perform sorting of good or bad (in this embodiment, ejection of defective products by the defective sheet ejection mechanism 41) on a PTP sheet-by-PTP sheet basis.

[0119] In addition, the periodic abnormality determination unit 72 compares the derived frequency at the "-1 interval" with the derived frequency at the "+1 interval," and determines whether or not a periodic abnormality exists based on a value (corrected frequency) obtained by adding the larger of these two derived frequencies to the derived frequency at the reference interval. This reduces the influence of using the number of sheets 101 as the abnormality occurrence interval L, that is, the influence of the abnormality occurrence interval L being one of two types, N or N+1, even when a periodic abnormality occurs, and enables more accurate determination of whether or not a periodic abnormality exists. As a result, it becomes possible to more accurately detect whether or not an abnormality exists in the sealing device 25.

[0120] Furthermore, the seal abnormality portion SI includes a severely abnormal portion JI and a mildly abnormal portion KI, which is an abnormal portion less severe than the severely abnormal portion JI. Therefore, the seal abnormality portion SI can be detected more reliably, and the presence or absence of an abnormality in the sealing device 25 can be detected more accurately.

[0121] Furthermore, an abnormality in the sealing device 25 can be detected at a stage where most of the sealing abnormality portions SI are only minor abnormality portions KI. Therefore, appropriate measures such as cleaning the sealing device 25 can be taken before major abnormality portions JI periodically occur (i.e., before defective PTP sheets 1 periodically occur). This allows for improved productivity and reduced costs in the manufacture of PTP sheets 1.

[0122] 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.

[0123] (a) In the above embodiment, the periodic abnormality determination unit 72 determines whether or not there is a periodic abnormality based on a value (corrected frequency) obtained by adding the larger of the derived frequencies in the "-1 interval" and the "+1 interval" to the derived frequency in the reference interval. Alternatively, the periodic abnormality determination unit 72 may determine whether or not there is a periodic abnormality based on the derived frequency in the reference interval without calculating the corrected frequency.

[0124] (b) The frequency acquisition unit 71 may derive the abnormality occurrence interval L and acquire the derived frequency for each of a plurality of regions obtained by dividing the PTP film 6 in its width direction. That is, the frequency acquisition unit 71 may derive the abnormality occurrence interval L and acquire the derived frequency based on the abnormality occurrence interval L for each of a plurality of regions R1, R2, R3, and R4 (hereinafter simply referred to as "R1 to R4") obtained by dividing the PTP film 6 in its width direction (see FIGS. 14 and 15). In this case, for example, by configuring the post-sealing inspection device 60 to detect an abnormal sealing portion SI for each of the regions R1 to R4, the frequency acquisition unit 71 can derive the abnormality occurrence interval L and acquire the derived frequency for each of the regions R1 to R4 using the inspection results (detection results) by the post-sealing inspection device 60.

[0125] The periodic abnormality determination unit 72 then determines whether or not there is a periodic abnormality based on the derived frequencies for each of the multiple regions R1 to R4. For example, when the derived frequencies for each of the regions R1 to R4 are acquired as in the example shown in Fig. 15, the periodic abnormality determination unit 72 compares the derived frequency at the reference interval with the periodic abnormality determination threshold value X1 for each of the regions R1 to R4. For example, for region R1, the periodic abnormality determination unit 72 compares the derived frequency (=5) for L=6 with the periodic abnormality determination threshold value X1.

[0126] Furthermore, the periodic abnormality determination unit 72 determines that a periodic abnormality exists when the derived frequency for at least one of the regions R1 to R4 exceeds the periodic abnormality determination threshold X1. On the other hand, the periodic abnormality determination unit 72 determines that no periodic abnormality exists when all of the derived frequencies for the regions R1 to R4 are equal to or less than the periodic abnormality determination threshold X1. Therefore, in the example shown in FIG. 15, although all of the derived frequencies for the regions R2, R3, and R4 are equal to or less than the periodic abnormality determination threshold X1, the derived frequency for the region R1 exceeds the periodic abnormality determination threshold X1, so the periodic abnormality determination unit 72 determines that a periodic abnormality exists. Of course, the periodic abnormality determination unit 72 may use a corrected frequency instead of the derived frequency for the determination.

[0127] By configuring the system to determine whether or not there is a periodic abnormality based on the derived frequency for each of the multiple regions, it is possible to more reliably prevent a sudden occurrence of a seal abnormality SI from affecting the determination, thereby further improving the accuracy of determining whether or not there is a periodic abnormality.

[0128] Furthermore, if multiple regions are adjacent to each other without overlapping, and an abnormal seal portion SI exists at the boundary between the regions, it may not be possible to properly detect the abnormal seal portion SI. Therefore, it is preferable to set the multiple regions so that they partially overlap, as shown in Figure 14. By setting them in this way, it is possible to more reliably prevent a decrease in the accuracy of detecting the abnormal seal portion SI.

[0129] (c) In the above embodiment, the derivation frequency is the total number of times the abnormality occurrence interval is derived, but the derivation ratio of the abnormality occurrence interval may also be used as the derivation frequency. In this case, in the example shown in Fig. 9, the derivation ratio when L = 6 is 1 (= 5 / 5), and in the example shown in Fig. 10, the derivation ratio when L = 6 is 3 / 7.

[0130] (d) In the above embodiment, only one inspection device (post-sealing inspection device 60) is provided, but other inspection devices may also be provided. However, the presence or absence of an abnormality in the sealing device 25 can be determined using only the detection results (inspection results) from the one inspection device (post-sealing inspection device 60).

[0131] (e) In the above embodiment, the PTP film 6 is configured such that the number of pocket portions 2 corresponding to one sheet is arranged along its width direction, but the PTP film 6 may be configured such that the number of pocket portions 2 corresponding to a plurality of sheets is arranged along its width direction. In other words, the PTP film 6 may have a plurality of rows of pre-sheet portions 101.

[0132] (f) In the above embodiment, the contents are tablets 5, but the type, shape, etc. of the contents are not particularly limited. The contents may be, for example, capsules, food, electronic components, or other things other than tablets 5.

[0133] (g) The configuration of the manufactured PTP sheet 1 is not limited to the above embodiment. For example, the arrangement and number of pockets 2 in each PTP sheet 1 are not limited to those in the above embodiment.

[0134] (h) In the above embodiment, the PTP sheet 1 is cited as the "blister sheet," but the technical concept of the present invention may be applied to a blister packaging machine capable of producing blister sheets other than the PTP sheet 1. [Explanation of symbols]

[0135] 1... PTP sheet (blister sheet), 2... pocket portion, 3... container film, 4... cover film, 5... contents (tablets), 6... PTP film (blister film), 10... PTP packaging machine (blister packaging machine), 20... film receiving roll (roll), 21... filling device (filling means), 24... heating roll (roll), 25... sealing device (sealing means), 37... sheet punching device (separating means), 50... sealing device abnormality detection system (sealing means abnormality detection system), 60... post-sealing inspection device (attachment state inspection means), 71... frequency acquisition unit (frequency acquisition means), 72... periodic abnormality determination unit (periodic abnormality determination means), 73... sealing device abnormality determination unit (sealing means abnormality determination means), 101... sheet planned portion, JI... seriously abnormal part, KI... slightly abnormal part, SI... sealing abnormal part.

Claims

1. a filling means for filling a pocket formed in the strip-shaped container film with contents; a sealing means having two predetermined rolls, the cover film being fed between the two rolls in a state where the cover film is superimposed on the container film, thereby attaching the cover film to the container film so as to close the opening side of the pocket portion filled with the contents by the filling means; a separating means for separating a blister sheet from a strip-shaped blister film formed by attaching the cover film to the container film; A sealing means abnormality detection system for detecting an abnormality in the sealing means relating to attachment of the cover film to the container film, which is used in a blister packaging machine comprising: an attachment state inspection means for detecting an abnormal seal portion of the blister film, which is a portion where an abnormality exists in the attachment state of the cover film to the container film; a frequency acquisition means for deriving an abnormality occurrence interval that correlates with the distance along the longitudinal direction of the blister film from the abnormal sealing portion detected by the attachment state inspection means to the next abnormal sealing portion detected by the attachment state inspection means after the abnormal sealing portion, and for acquiring the frequency of the abnormality occurrence interval for each abnormality occurrence interval; a periodic abnormality determination means for determining whether or not there is a periodic abnormality in the attachment state of the cover film to the container film based on the derived frequency acquired by the frequency acquisition means; A sealing means abnormality detection system characterized by comprising a sealing means abnormality judgment means that judges whether or not there is an abnormality in the sealing means related to the attachment of the cover film to the container film based on the judgment results by the periodic abnormality judgment means.

2. the blister film is configured such that pre-sheet portions to be cut off by the cutting means to become the blister sheets are aligned along the longitudinal direction of the blister film, the attachment state inspection means is capable of detecting the abnormal seal portion for each of the intended sheet portions, The sealing means abnormality detection system described in claim 1, characterized in that the frequency acquisition means is configured to derive the number of the sheet intended portions corresponding to the distance from the sealing abnormality portion detected by the attachment state inspection means to the sealing abnormality portion detected by the attachment state inspection means next to the sealing abnormality portion as the abnormality occurrence interval.

3. The sealing means abnormality detection system according to claim 2, characterized in that the periodic abnormality determination means is configured to compare the derived frequency at the abnormality occurrence interval obtained by subtracting 1 from the abnormality occurrence interval at which the derived frequency was maximum as a reference interval with the derived frequency at the abnormality occurrence interval obtained by adding 1 to the reference interval, and to determine whether or not there is a periodic abnormality based on the value obtained by adding the larger of these two derived frequencies to the derived frequency at the reference interval.

4. The attachment state detection means is configured to use a predetermined first threshold value to detect a severely abnormal portion where the attachment state of the cover film to the container film is poor, and to use a second threshold value different from the first threshold value to detect a mildly abnormal portion where the attachment state is milder than the severely abnormal portion, 2. The sealing means abnormality detection system according to claim 1, wherein the sealing abnormality portion includes the severe abnormality portion and the mild abnormality portion.

5. the frequency acquisition means is configured to derive the abnormality occurrence interval and acquire the derived frequency for each of a plurality of regions obtained by dividing the blister film in its width direction, 2. The sealing means abnormality detection system according to claim 1, wherein the periodic abnormality determination means determines whether or not the periodic abnormality exists based on the derived frequency for each of the plurality of regions.

6. A blister packaging machine comprising the sealing means abnormality detection system according to claim 1.

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