Foreign body inspection device and foreign body inspection method

Abstract

A foreign matter inspection device and a foreign matter inspection method are provided that can reduce manufacturing costs without reducing the accuracy of foreign matter detection. [Solution] The system includes a base that rotatably holds a container (10), a camera (20) that is fixed in position and can capture images of the inside of one container (10) at multiple different positions, and a light (30) that is provided at a position facing the camera (20) on the base and irradiates the container (10) with light. The light (30) is an illumination unit that can switch its light-emitting position depending on the imaging position of the container (10). Light is irradiated from the light (30) corresponding to each position of the container (10) that is imaged by the camera (20), and the inside of the container (10) is imaged by the camera (20), and the presence or absence of foreign matter is determined based on the multiple images obtained.

Description

[Technical Field]

[0001] The present invention relates to a foreign matter inspection device and a foreign matter inspection method. [Background technology]

[0002] Patent Document 1 describes a foreign matter inspection device that inspects for the presence or absence of foreign matter by utilizing transmission and reflection through color separation. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-267613 Summary of the Invention [Problem to be solved by the invention]

[0004] In a foreign body inspection device such as that described in Patent Document 1, when multiple images are taken and image subtraction is performed to check for the presence or absence of foreign bodies, the relative positions of the camera, container, and lighting are important for detection accuracy, and an oscillation mechanism is required to move the camera and lighting at the same speed as the container as it is continuously transported. However, oscillation mechanisms have a complex structure, are large-scale, and are expensive. Furthermore, if the container is fed intermittently rather than continuously, the liquid level in the container will fluctuate, making it impossible to inspect the liquid level.

[0005] The present invention is intended to solve the above-mentioned problems of the conventional art, and has an object to provide a foreign matter inspection device and a foreign matter inspection method that can reduce manufacturing costs without reducing the accuracy of foreign matter detection. [Means for solving the problem]

[0006] The present invention is a foreign matter inspection device for detecting foreign matter mixed in a liquid filled in a container, comprising: a rotating unit that rotatably holds the container; an imaging unit that is fixed in position and can image the inside of one of the containers at a plurality of different positions; and an illumination unit that is provided at a position opposite the imaging unit with respect to the rotating unit and irradiates the container with light, the illumination unit being an illumination unit that can irradiate light by switching a light-emitting position depending on the imaging position of the container, and the container that is imaged by the imaging unit after the rotating unit is stopped. when the container is transported to a first position, the illumination unit irradiates light from a first region thereof and the imaging unit captures an image of the inside of the container; when the container is transported from the first position to a second position, the illumination unit is switched from the first region thereof to a second region thereof, the illumination unit irradiates light, and the imaging unit captures an image of the inside of the container; when the container is transported from the second position to a third position, the illumination unit is switched from the second region thereof to a third region thereof, the illumination unit irradiates light, and the imaging unit captures an image of the inside of the container; The method is characterized in that it determines whether or not there is a foreign substance based on the multiple images obtained. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a foreign matter inspection device and a foreign matter inspection method that can reduce manufacturing costs without reducing the precision of foreign matter detection. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a schematic configuration diagram of a foreign matter inspection device according to an embodiment of the present invention. [Figure 2] FIG. 2 is a block diagram of a computer used in the foreign matter inspection apparatus according to the present embodiment. [Figure 3] 2 is a schematic diagram showing the positional relationship between a camera and lighting in the foreign matter inspection device according to the present embodiment. FIG. [Figure 4] 4 is a flowchart showing the operation of the foreign matter inspection apparatus according to the present embodiment. [Figure 5A] 3 is a schematic diagram showing a state of an illumination unit in the foreign matter inspection device according to the present embodiment when a container is at a first position. FIG. [Figure 5B] 10 is a schematic diagram showing a state of an illumination unit in the foreign matter inspection device according to the present embodiment when the container is in a second position. FIG. [Figure 5C] 10 is a schematic diagram showing a state of an illumination unit in the foreign matter inspection device according to the present embodiment when the container is in a third position. FIG. [Figure 6] 5A and 5B are diagrams illustrating image processing of the foreign matter inspection device according to the present embodiment. [Figure 7]10A and 10B are diagrams illustrating another operation of the foreign matter inspection device according to the present embodiment. [Figure 8] 10A and 10B are diagrams illustrating image processing by another operation of the foreign matter inspection device according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiment, and various modifications and application examples within the technical concept of the present invention are also included within its scope. FIG. 1 is a schematic diagram of a foreign matter inspection device according to this embodiment. As shown in FIG. 1, the foreign body inspection device 1 includes an inspection rotor 3 having a plurality of bases 2 (rotating parts) arranged in a ring shape. The bases 2 rotatably hold containers 10 (containers to be inspected). The rotation of the bases 2 causes the containers 10 to rotate. The inspection rotor 3 also rotates at a predetermined speed. The inspection rotor 3 also rotates at a uniform speed, continuously transporting the containers 10. The containers 10 are, for example, transparent bottles such as vials or ampoules filled with a chemical solution (liquid, contents).

[0010] The foreign substance inspection device 1 also includes a transport mechanism 4 for transporting the container 10 into and out of the inspection rotor 3. This transport mechanism 4 is composed of a combination of multiple star wheels 5. The container 10 introduced into the supply port of the inspection rotor 3 by the star wheels 5 is transported to the inspection position by the rotation of the inspection rotor 3. The inspection position is a position where a camera 20 and a light 30 are provided. The container 10 moves at a constant speed. Furthermore, the container 10 rotates by the rotation of the base 2 until just before being transported to the inspection position. The rotation speed of the base 2 is changed as appropriate to rotate the liquid inside, depending on the liquid agent, liquid quality, shape of the container, etc.

[0011] A camera 20 (imaging unit) is disposed inside the inspection rotor 3. The camera 20 is composed of a CCD (Charge Coupled Device) camera or the like. A light 30 is disposed outside the inspection rotor 3. The light 30 irradiates the container 10 with light and is provided at a position facing the camera 20 with respect to the base 2. Note that the camera 20 may be located outside the inspection rotor 3 and the light 30 may be located inside the inspection rotor 3, and these can be changed as appropriate.

[0012] FIG. 2 is a block diagram of a computer used in the foreign matter inspection device according to this embodiment. As shown in FIG. 2, the foreign substance inspection apparatus 1 includes a control unit 40. The control unit 40 is implemented by one or more computers 900, each computer having a CPU 901, a RAM 902, a ROM 903, an HDD 904, a communication I / F 905, an input / output I / F 906, and a media I / F 907. The communication I / F 905 is connected to an external communication device 915. The input / output I / F 906 is connected to an input / output device 916. The media I / F 907 reads and writes data from a recording medium 917. Furthermore, the CPU 901 executes a program (application) loaded into the RAM 902 to configure an image processing unit 50 (see FIG. 6). This program can be distributed via a communication line or recorded on a recording medium 917 such as a CD-ROM. The control unit 40 also controls the rotation speed of the inspection rotor 3, the ON / OFF of the rotational movement of the base 2, the ON / OFF of the camera 20, the ON / OFF of the lighting 30, and the like.

[0013] 3 is a schematic diagram showing the positional relationship between the camera and the lighting in the foreign matter inspection device according to this embodiment. For ease of explanation, the container 10 and the camera 20 are shown in perspective, and the lighting 30 is shown in plan view. For ease of explanation, an example in which images are captured at three imaging positions, positions A, B, and C, will be described. As shown in FIG. 3, the camera 20 has a camera body 21 and a wide-angle lens 22, and the wide-angle lens 22 is disposed so as to face the side from which the container 10 is conveyed. The camera 20 is fixed to a base (not shown) on which the foreign matter inspection device 1 is provided. That is, the foreign matter inspection device 1 of this embodiment is not equipped with an oscillation mechanism for causing the camera 20 to track at the same speed as the container 10. In FIG. 3, the solid line indicates the current state of the container 10 at position A (first position), the two-dot chain line indicates the state of the container 10 at position B (second position) after being conveyed from position A, and the two-dot chain line indicates the state of the container 10 at position C (third position) after being conveyed from position B. In this way, the container 10 is conveyed at a constant speed from position A to position C by the rotation of the inspection rotor 3 by the conveying mechanism 4 (see FIG. 1). The wide-angle lens 22 has an angle of view that can capture the container 10 from position A to position C within its imaging range.

[0014] The lighting 30 is disposed on the opposite side of the container 10 from the camera 20. The lighting 30 is an illumination unit that can switch its light-emitting position to irradiate light depending on the imaging position of the container 10. In this embodiment, the lighting 30 is configured as a single lighting unit, and is capable of switching its light-emitting position (light-emitting area). Note that the term "single lighting unit" means that the lighting is not configured as a separate unit. Furthermore, the lighting 30, like the camera 20, is fixed to a base (not shown) on which the foreign matter inspection device 1 is mounted. In other words, the foreign matter inspection device 1 of this embodiment is not equipped with an oscillation mechanism that causes the lighting 30 to follow the container 10 at the same speed.

[0015] The lighting 30 is configured as a plate-like surface emitting light using an LED (Light Emitting Diode), an organic light emitting diode (OLED), a light guide plate, or the like. The lighting 30 is configured to emit light to illuminate the entire container 10 or the liquid in the container 10 from the bottom to the liquid surface. The lighting 30 can switch its light-emitting position (light-emitting area) by switching the LED ON / OFF position. For example, when the container 10 reaches position A, area a (first area) of the lighting 30 facing the container 10 at position A emits light. When the container 10 reaches position B, area b (second area) of the lighting 30 facing the container 10 at position B emits light. When the container 10 reaches position C, area c (third area) of the lighting 30 facing the container 10 at position C emits light. The light-emitting position (area a, area b, area c) of the lighting 30 can be switched by switching the LED's light-emitting position.

[0016] Next, the operation of the foreign matter inspection apparatus 1 will be described with reference to Fig. 4 and Fig. 5A, Fig. 5B, and Fig. 5C. Fig. 4 is a flowchart showing the operation of the foreign matter inspection apparatus according to this embodiment. Fig. 5A is a schematic diagram showing the state of the illumination unit in the foreign matter inspection apparatus according to this embodiment when the container is in a first position, Fig. 5B is a schematic diagram showing the state of the illumination unit in the foreign matter inspection apparatus according to this embodiment when the container is in a second position, and Fig. 5C is a schematic diagram showing the state of the illumination unit in the foreign matter inspection apparatus according to this embodiment when the container is in a third position.

[0017] As shown in FIG. 4, in step S1, when the container 10 is transported by the inspection rotor 3, the control unit 40 rotates the base 2 to rotate the container 10 (a process of rotatably holding the container 10). The rotation of the container 10 rotates the liquid in the container 10, and if foreign matter is present, the foreign matter also rotates along with the liquid. The container 10 is transported at a constant speed (uniform velocity) by the inspection rotor 3 (see FIG. 1). Then, just before the container 10 reaches position A, the rotation of the base 2 stops, and the rotation of the container 10 also stops. By stopping the container 10, any dirt or scratches on the container surface do not move, and the foreign matter moves along with the liquid.

[0018] Then, in step S2, when the container 10 reaches position A, the control unit 40 causes the area a of the illumination 30 to emit light (a step of irradiating light at position A) and captures an image of the container 10 at position A with the camera 20 (a step of capturing an image of the inside of the container 10 at position A). When the area a of the illumination 30 emits light, the entire liquid in the container 10 at position A is irradiated with light.

[0019] Then, in step S3, when the container 10 reaches position B from position A, the control unit 40 causes the area b of the illumination 30 to emit light (a step of irradiating light at position B), and also causes the camera 20 to capture an image of the container 10 at position B (a step of capturing an image of the inside of the container 10 at position B). By emitting light from area b of the illumination 30, the entire liquid in the container 10 at position B is irradiated with light.

[0020] Then, in step S4, when the container 10 reaches position C from position B, the control unit 40 causes the area c of the illumination 30 to emit light (a step of irradiating light at position C), and also causes the camera 20 to capture an image of the container 10 at position C (a step of capturing an image of the inside of the container 10 at position C). As the area c of the illumination 30 emits light, the entire liquid in the container 10 at position C is irradiated with light.

[0021] Then, in step S5, the control unit 40 compares the image of the container 10 at position A, the image of the container 10 at position B, and the image of the container 10 at position C to determine whether or not a foreign object is present (a process of determining whether or not a foreign object is present in the container 10).

[0022] 5A, when the container 10 reaches position A, region a of the illumination 30 emits light, and the light is irradiated onto the container 10 at position A. At the same time that the light is irradiated onto the container 10 at position A, the camera 20 captures an image of the container 10 at position A (the liquid in the container 10). Note that the container 10 at position A is configured to fit within the angle of view of the camera 20, so that the container 10 at position A can be imaged by the camera 20, whose position is fixed.

[0023] As shown in FIG. 5B, when the container 10 moves from position A to position B, region b of the illumination 30 emits light, and the light is irradiated onto the container 10 at position B. At the same time that the light is irradiated onto the container 10 at position B, the camera 20 captures an image of the container 10 at position B (the liquid in the container 10). Note that the container 10 at position B is configured to fit within the angle of view of the camera 20, so that the container 10 at position B can be imaged by the camera 20, whose position is fixed.

[0024] As shown in FIG. 5C, when the container 10 moves from position B to position C, the area c of the illumination 30 emits light, and the light is irradiated onto the container 10 at position C. At the same time that the light is irradiated onto the container 10 at position C, the camera 20 captures an image of the container 10 at position C (the liquid in the container 10). Note that the container 10 at position C is configured to fit within the angle of view of the camera 20, so the container 10 at position C can be imaged by the camera 20, whose position is fixed.

[0025] In this way, even with a configuration in which the camera 20 and the lighting 30 are fixed, the camera 20 can capture images of the container 10 in the range from position A to position C. Furthermore, because the light-emitting position of the lighting 30 can be switched between area a and area c, the positional relationship between the camera 20, the container 10, and the lighting 30 (light-emitting unit) can be kept constant whether the container 10 is at position A, position B, or position C. This makes it possible to obtain images with the same positional relationship, thereby achieving foreign body detection accuracy equivalent to that of conventional foreign body inspection devices equipped with an oscillation mechanism.

[0026] FIG. 6 is a diagram for explaining image processing in the foreign matter inspection device according to this embodiment. As shown in FIG. 6, the image processing unit 50 performs a process of superimposing a first image 51a of the container 10 captured at position A, a second image 51b of the container 10 captured at position B, and a third image 51c of the container 10 captured at position C. The container 10 at position A and the liquid therein are captured as image 101a at the left end of image 51a. The container 10 at position B and the liquid therein are captured as image 101b at the center of image 51b. The container 10 at position C is captured as image 101c at the right end of image 51c. Foreign objects 60a, 60b, and 60c are captured in all of the images 51a, 51b, and 51c. Note that the foreign objects 60a, 60b, and 60c are all the same foreign object. When the container 10 stops, the liquid and foreign objects in the container 10 continue to rotate due to inertial force. The liquid maintains the same shape, so only the foreign object appears to be moving.

[0027] Furthermore, the image processing unit 50 extracts a difference image 51d by performing differential processing on the three images 51a, 51b, and 51c. The presence or absence of a foreign object is determined based on this difference image 51d. At this time, the outline of the container 10 appears in the same position in all of the images 51a, 51b, and 51c, so it is not determined to be a foreign object. Furthermore, although the liquid in the container 10 rotates and moves, it maintains the same shape and is therefore not determined to be a foreign object. Furthermore, if a foreign object is mixed in the liquid, the positions of the foreign objects 60a, 60b, and 60c will appear different, so it can be determined that it is a foreign object.

[0028] As described above, the foreign matter inspection device 1 of this embodiment includes the base 2 that rotatably holds the container 10, the camera 20 that is fixed and can capture images of the inside of one container 10 at multiple different positions (position A, position B, position C), and the illuminator 30 that is located opposite the camera 20 on the base 2 and irradiates the container 10 with light. The illuminator 30 is an illumination unit that can irradiate light by switching its light-emitting position (area a, area b, area c) depending on the imaging position of the container 10. After the base 2 is stopped, the illuminator 30 irradiates light corresponding to each position (position A, position B, position C) of the container 10 that the camera 20 images, and the camera 20 images the inside of the container 10. The presence or absence of foreign matter is determined based on the obtained multiple images 51a, 51b, and 51c. This eliminates the need for a mechanism (oscillating mechanism) that tracks the camera 20 and the illuminator 30 with respect to the container 10, thereby simplifying the mechanism and reducing manufacturing costs.

[0029] FIG. 7 is a diagram illustrating another operation of the foreign matter inspection device according to this embodiment. As shown in FIG. 7, in the foreign matter inspection device 1A, a container 10A reaches position C, and the next container 10B, which is being transported by the inspection rotor 3 (see FIG. 1), reaches position A. Note that the container 10A has already been imaged by the camera 20 at positions A and B and has reached position C. At this time, the area c of the illumination 30 is illuminated, and the camera 20 images the container 10A at position C. At the same time, the area a of the illumination 30 is illuminated for the container 10B at position A, irradiating the container 10B with light, and the camera 20 images the container 10B at position A. Note that, although not shown, when the container 10B is transported from position A to position B, the area b of the illumination 30 is illuminated, and the camera 20 images the container 10B at position B. Then, when the container 10B is transported from position B to position C, the area c of the illumination 30 is illuminated, and the camera 20 images the container 10B at position C.

[0030] FIG. 8 is a diagram for explaining image processing by another operation of the foreign matter inspection device according to this embodiment. As shown in FIG. 8, the image processing unit 50 performs a process of superimposing a first image 52a of the container 10B captured at position A, a second image 52b of the container 10B captured at position B, and a third image 52c of the container 10B captured at position C. The container 10B at position A is shown at the left end of the image 52a as image 102a (the first image of the container 10B). The container 10A at position C is shown at the right end of the image 52a as image 101c (the third image of the container 10A). The container 10B at position B is shown at the center of the image 52b as image 102b (the second image of the container 10B). The container 10B at position C is shown at the right end of the image 52c as image 102c (the third image of the container 10B). Furthermore, the container next to position A is shown at the left edge of image 52c as image 103a (the first image of the container next to container 10B). Foreign objects 60a, 60b, and 60c in container 10B are shown in all of images 52a, 52b, and 52c. Note that foreign objects 60a, 60b, and 60c are all the same foreign object. Furthermore, image processing unit 50 extracts differential image 52d by performing differential processing on the three images 52a, 52b, and 52c, and determines the presence or absence of foreign objects based on this differential image 52d.

[0031] As described above, in the foreign matter inspection device 1A, the camera 20 captures images of the container 10A and the next container 10B together (so that two containers 10 are captured in one image data) while irradiating light from areas c and a of the illumination 30 onto positions C and A between the container 10A and the next container 10B supplied by the transport mechanism 4. This allows the interval between the container 10A and the container 10B (the next container) to be shortened, thereby improving the inspection speed.

[0032] The present invention is not limited to the above-described embodiment, and can include various modifications. For example, in the above-described embodiment, a configuration is described in which images are acquired at three locations, namely, positions A, B, and C, to determine the presence or absence of a foreign substance, but the number of locations is not limited to three, and images may be acquired at four or more locations to determine the presence or absence of a foreign substance.

[0033] In addition, in the embodiment shown in Figures 7 and 8, the container 10A at position C and the container 10B (next container) at position A are configured to fit into one image 52a, but if the positional relationship between the camera, container, and lighting can be made the same at any of positions A, B, and C, it is also possible to acquire the container 10A at position C (the third image of container 10A), the container 10B at position B (the second image of container 10B), and the container at position A (the first image of container) as one image, and determine the presence or absence of foreign matter. [Explanation of symbols]

[0034] 1,1A Foreign body inspection device 2 Base (rotating part) 3 Inspection rotor 4. Transport mechanism 10,10A,10B container 20 Camera (imaging unit) 30 Lighting (Lighting Department) 40 Control Unit 50 Image processing section

Claims

1. A foreign matter inspection device for detecting foreign matter mixed in a liquid filled in a container, a rotating part that rotatably holds the container; an imaging unit that is fixed in position and can capture images of the inside of one container at a plurality of different positions; an illumination unit that is provided at a position facing the imaging unit with respect to the rotating unit and that irradiates the container with light; the illumination unit is an illumination unit that can switch a light-emitting position and irradiate light according to an imaging position of the container, A foreign body inspection device characterized in that, when the container to be imaged by the imaging unit is transported to a first position after the rotating unit is stopped, light is irradiated from a first region of the illumination unit and an image of the inside of the container is taken by the imaging unit, when the container is transported from the first position to a second position, the illumination unit is switched from the first region to a second region, light is irradiated, and an image of the inside of the container is taken by the imaging unit, and when the container is transported from the second position to a third position, the illumination unit is switched from the second region to a third region, light is irradiated, and an image of the inside of the container is taken by the imaging unit, and the presence or absence of foreign bodies is determined based on the multiple images obtained.

2. In the foreign body inspection device according to claim 1, The imaging unit images the container and the next container supplied by the conveying mechanism together while light is irradiated from the first area and the third area of ​​the illumination unit onto the positions of the container and the next container supplied by the conveying mechanism.

3. A foreign matter inspection method for detecting foreign matter mixed in a liquid filled in a container, comprising: rotatably holding the container; irradiating the container whose rotation has stopped with light from a lighting unit at a different position; a step of, after stopping the rotation of the container, irradiating the container with light from a first region of the illumination unit and capturing an image of the inside of the container with an imaging unit when the container is transported to a first position, switching the illumination unit from the first region to a second region, irradiating light, and capturing an image of the inside of the container with the imaging unit when the container is transported from the first position to a second position, and switching the illumination unit from the second region to a third region, irradiating light, and capturing an image of the inside of the container with the imaging unit when the container is transported from the second position to a third position; and determining whether or not a foreign object is present in the container based on the plurality of captured images.

Images