Inspection unit for containers and method for determining the quality of containers

Abstract

1. An inspection unit for containers (11), in particular for metal containers used in metered dose inhalers or for the manufacture of batteries, comprising a visual inspection unit (9) with a camera unit (20), a transport unit (8) where images of individual containers can be captured from different viewing angles by different camera units, each camera unit simultaneously capturing a plurality of containers in an image comprising a plurality of image portions (24) comprising images of an outer surface portion of each of the plurality of containers from a different viewing angle, the image portions comprising images of an outer side surface portion (22) and an outer bottom surface portion (19) of each container, the sum of the images of the outer side surface portions covering the entire outer side surface of the container, and a processing unit for processing the captured image portions and determining an inspection result.

Description

Technical Field

[0001] The present invention relates to an inspection unit for determining the quality of containers, particularly metal containers used for the manufacture of metered-dose inhalers or batteries, and a method for determining the quality of containers.

Background Art

[0002] High quality standards are set for the manufacture of metal container-shaped products in many areas, particularly in battery production or the medical field. In the production of battery containers, for example, high surface quality and dimensional accuracy are required. Only battery containers that meet the specified dimensions after production ensure the technical functionality and safety of the final battery product. The medical industry also has similar requirements. Containers to be further processed into cartridges for metered-dose inhalers, for example, must meet high quality requirements in order to ensure the functionality and quality of medical products.

[0003] The manufacture of such containers, for example battery containers, is often carried out by batch and queue processes in a production line including at least one deep drawing station for forming the drawn battery container. Deep drawing is brought about in combination with at least one punching machine having protrusions forming the surface, and means for stretching the sheet material across the punching machine while the rear half is moved laterally with respect to the material, particularly at least one die for receiving the formed material. A typical deep drawing process is described, for example, in U.S. Patent No. 2,989,019, which is incorporated herein by reference.

[0004] As defined in the industrial standard DIN 8584, deep drawing is a forming process that occurs under a combination of tensile and compressive conditions. During deep drawing, the material is subjected to high stress loads. A characteristic of deep drawing is the high pressure involved in the operation, approximately 100,000 pounds per square inch (psi). Lubricants are used to handle such forces and to avoid deformation of the punching machine and die. Under such pressures, the drawing lubricant should cool the die and the workpiece, provide boundary lubrication between the die and the workpiece, prevent intermetallic adhesion or welding, and mitigate the impact on the die during the drawing operation.

[0005] In subsequent stages, the formed parts are moved to a cleaning and drying area to remove the drawing lubricant. After the above production steps, the formed parts are often inspected to ensure they meet specified quality standards. Accuracy and high material quality are becoming increasingly important for the safety of lithium-ion (Li-ion) batteries. Although development standards for Li-ion batteries have steadily improved in recent years, accidents such as explosions and fires are still caused by the uncontrolled release of chemically stored energy in the battery, for example, due to mechanical damage and material defects. Therefore, it is important that the battery container can withstand high pressure without rupturing even in the event of battery malfunction. Typically, the quality level is ensured through random sampling and manual inspection of metal battery containers.

[0006] However, in high-productivity production lines for expanding lithium-ion batteries, random sampling is not sufficiently accurate, leading to a demand for the development of automated quality inspection units.

[0007] Currently, it is common to use camera systems to visually inspect the surface area of ​​formed products. Through comparison of captured images with reference data, visual inspection systems can detect various defects within the material surface. However, in high-precision manufacturing processes, material defects such as minute pores or cuts, or internal structural material defects, often go undetected, significantly impacting the safety of the final battery, especially lithium-ion batteries. In this regard, it is standard practice to visually inspect containers by rotating them and moving them past camera units, thereby allowing the cameras to visually capture the entire outer surface of the container. The image data is then compared with predetermined target data to determine the quality of the product. Another approach is to pass the containers through a series of camera units that visually inspect the container sections in sequence. However, with respect to increasing production speeds and shorter production times in high-productivity manufacturing lines, such inspection systems prove inefficient.

[0008] The objective of this invention is to improve the quality inspection of containers within a high-productivity manufacturing line so as to ensure that containers are inspected in a fast and efficient manner. [Overview of the project] [Means for solving the problem]

[0009] The object of the present invention is to be solved by an inspection unit as defined in claim 1 and a method as defined in claim 14. Further preferred embodiments of the present invention are disclosed in the following description and dependent claims.

[0010] According to the present invention, an inspection unit for determining the quality of a container comprises a visual inspection unit. The visual inspection unit comprises multiple camera units that define a visual inspection area throughout the entire field of view, consisting of the entire field of view of the camera units, in which the container is visually inspected by the multiple camera units, i.e., the multiple camera units are concentrated on the visual inspection area and inspect all containers within the entire field of view of all camera units. A transport unit is adapted to transport the containers through the visual inspection area for visual inspection.

[0011] The transport unit and camera units are coordinated, for example, arranged, so that images of individual containers can be captured within a visual inspection area by different camera units of multiple camera units, for example, by a subset of multiple camera units of the visual inspection unit, or by all of the multiple camera units, from different field of view angles, in other words, from different viewpoints, for example, due to the spatial distribution of the camera units. In one embodiment of the present invention, the transport unit and multiple camera units are coordinated so that images of individual containers can be captured within a visual inspection area by different camera units from different field of view angles at the same time, i.e., simultaneously. Furthermore, the transport unit and multiple camera units are coordinated so that each of the multiple camera units can simultaneously capture multiple containers in an image, i.e., multiple containers may be in the field of view of each camera unit at the same time, such that a camera unit can capture all containers in its field of view in an image, and each container in the image is captured from a different field of view angle due to the distribution of the containers in the field of view. The image includes multiple image portions, each image portion including images of the respective outer surface portions of the multiple containers from different field of view angles. In other words, each of the multiple containers in the image is captured, for example, photographed, from a different viewpoint due to the distribution of the containers within the camera unit's field of view, and each of the outer surface segments of the multiple containers is captured.

[0012] The image portions captured by the plurality of camera units include images of the outer side surface portions (i.e., outer covering wall portions or outer side wall portions) and outer bottom surface portions of each of the plurality of containers, and the sum of the images of the outer side surface portions covers the entire outer side surface of the container. Furthermore, a processing unit is configured to be operably coupled to the plurality of camera units and to process the image portions captured for each of the plurality of containers and to determine an inspection result, the step of determining the inspection result includes the step of comparing image parameters with predetermined parameters.

[0013] Thus, visual inspection of the outer surface of the container is distributed among several camera units; that is, scanning of the entire outer side surface (outer sidewall surface) and outer bottom surface of each container is acquired by using multiple camera units. This enables surface scanning that covers 100% of the outer sidewall and outer bottom of each container. Furthermore, each camera unit can visually inspect several containers simultaneously.

[0014] According to a further embodiment of the present invention, the multiple camera units are configured to capture multiple images of the multiple containers as the containers are transported through the visual inspection area, such that the transport movement of the containers changes the field of view of the camera unit on each of the multiple containers. This allows the camera units to capture different surface segments of the containers.

[0015] The processing unit may be, for example, a microprocessor that receives image data from the camera unit. The processing unit may be configured to divide a single image provided by the camera unit into individual image segments or parts based on fixed parameters. For example, the image segments may be predetermined segments within the image, predetermined by, for example, size and position. The camera unit is coordinated with the transport unit in such a way that the camera unit captures an image when the container is in the camera unit's field of view, corresponding to the position of an image segment in the image. In one embodiment of the present invention, the processing unit is adapted to process the image from the camera unit using software suitable for object recognition, thereby the software recognizes individual containers in the image and then divides the image into segments, i.e., image segments, so that each segment contains an image of a surface segment of the container. Software already commercially available can be used for this purpose.

[0016] The comparison of image data from a portion of an image with stored reference data can be achieved in many ways. For example, parameters such as grayscale values ​​or contrast thresholds within predetermined locations may be assigned to each image within the image portion. These values ​​are compared with stored reference values. The processing unit can then identify visual differences and detect visual material defects such as scratches or equivalents. Visual inspection of the container from different viewing angles significantly improves the speed and quality of the decision-making process.

[0017] The processing unit may be adapted to store the captured images required to evaluate the container until all required images for evaluation are available, and then to begin the evaluation. However, the processing unit may also be adapted to perform evaluation of individual detected surface segments of the container while the inspection process is still ongoing.

[0018] The container has a cylindrical molded body with peripheral side walls having outer side wall surfaces (outer side surfaces, outer covering wall surfaces), an opening (container opening), and a bottom from which the side walls extend. The opening of the container is located opposite the container body to the container bottom. The side walls of the container may be cylindrical in shape. However, it is also possible to visually inspect containers with slanted or uneven side wall divisions.

[0019] According to a further embodiment of the present invention, the transport unit is provided in the form of a robotic arm. According to a further embodiment of the present invention, the transport unit comprises a gripping mechanism configured to grip and hold a plurality of containers, for example, in a suspended manner. The gripping mechanism may comprise a base element, for example, a plate-shaped gripping unit, with a plurality of grippers, each configured to hold one or more containers. The gripping mechanism may be based on different principles. For example, the gripping mechanism may include a gripper arm as a gripper, which holds the container by engaging with and clamping it. The gripping mechanism may also include a vacuum gripper that uses a vacuum or suction cup and holds the container using negative pressure. Other gripping mechanisms, such as magnetic grippers, are also conceivable.

[0020] According to a further embodiment of the present invention, the gripping mechanism includes one or more light sources for illuminating at least a portion of the visual inspection area. According to yet another embodiment, one or more light sources are provided within the area of ​​a camera unit, oriented in the viewing direction of the camera unit, and illuminating the visual inspection area. According to yet another embodiment of the present invention, a plurality of camera units are surrounded by one or more light sources.

[0021] Visual inspection of the container is performed as the container is transported through the visual inspection area. In particular, according to a further embodiment of the present invention, the visual inspection of the container may be performed during the continuous transport movement of the container through the inspection unit. For example, the transport unit may be configured to transport the container through the visual inspection area in a non-stop manner. Alternatively, the transport movement may be performed step by step, meaning that the container is moved progressively through the visual inspection area.

[0022] According to a further embodiment of the present invention, the processing unit is adapted to process multiple images (i.e., image portions) of a container from different camera units and from different field of view. In one embodiment of the present invention, the processing unit is configured to process at least three images from each of three camera units. Thus, each container is captured by multiple camera units, and individual image portions are processed by the processing unit for evaluation.

[0023] According to a further embodiment of the present invention, the visual inspection unit is adapted to inspect each container by processing images provided by at least three camera units.

[0024] According to a further embodiment of the present invention, the processing unit is configured to process at least nine image portions for each container, each containing images of the outer surface portion of the container from different viewing angles.

[0025] According to a further embodiment of the present invention, a plurality of camera units are arranged to have overlapping image areas.

[0026] According to a further embodiment of the present invention, the processing unit is configured to generate a stitched image of each container based on the image portions, and the parameters of the resulting stitched image are compared by the processing unit with a predetermined set of parameters. The processing unit can thus generate, from the individual images of the containers within the image portions of the images captured by the plurality of camera units, an overall image of the outer surface of the container, for example, a virtual image of the entire outer surface of the container. This stitched image can be compared with default values for determining the quality of the surface and shape of the container.

[0027] According to a further embodiment of the present invention, the camera units are arranged in an array arrangement, for example, a one-dimensional array arrangement in which adjacent camera units are aligned with each other along an axis perpendicular to the direction of the conveying movement of the conveying unit.

[0028] According to a further embodiment of the present invention, the conveying unit is adapted to convey a plurality of containers through the visual inspection area in an array arrangement. For example, the containers may be arranged in a one-dimensional array extending in the conveying direction, i.e., the containers are arranged in sequence in the conveying direction. The containers may also be arranged in a one-dimensional array extending transversely to the conveying direction such that the containers within the array are conveyed together into the visual inspection area. The containers may also be conveyed by the conveying unit through the visual inspection area in a two-dimensional array arrangement, for example, a matrix grid arrangement or a lattice arrangement, the two-dimensional array arrangement comprising at least two rows of containers, each row extending in a direction transverse to the direction of conveyance such that the containers within each row are conveyed simultaneously through the visual inspection area. The two-dimensional array arrangement basically comprises two or more one-dimensional arrays of containers.

[0029] According to a further embodiment of the present invention, the conveying unit is adapted to convey the containers through the visual inspection area in an array arrangement, i.e., a one-dimensional array arrangement or a two-dimensional array arrangement (matrix arrangement). In the array arrangement, the number n of the containers in a row, for example, in a direction perpendicular or transverse to the conveying direction, is defined by n >= 1, and the number m of the camera units for inspecting the containers is m = n + 2.

[0030] By arranging the containers in an array or matrix arrangement, for example, each of the camera units arranged in an array arrangement can inspect each of the containers from different viewpoints within its field of view as the array or matrix-arranged containers pass through. A single camera unit captures multiple images of the container as the container passes through and occupies different positions within the field of view of the camera unit during the conveying movement.

[0031] According to a further embodiment of the present invention, the containers are conveyed through the visual inspection area in a suspended manner. It is also conceivable to convey the containers with the container opening oriented upward or in a horizontally aligned state, as long as the camera unit is aligned in such a way that the relevant section of the container can be captured as described above.

[0032] According to a further embodiment of the present invention, the camera unit is located below the path of movement of the conveying unit so that the camera unit can visually inspect the containers from below.

[0033] According to a further embodiment of the present invention, the inspection unit comprises a tube assembly with a plurality of tubes and trays, the transport unit being adapted to transport containers into the tubes in such a manner that each tube receives one container after a visual inspection, i.e., after passing through a visual inspection area, the tubes being adapted to guide the containers onto the trays by gravity, and the tubes being at least partially inclined in the direction of fall such that the distance between adjacent containers on the trays is shorter than that on the transport unit. Thus, the containers are brought closer together as they are guided through the tubes, and then, after the visual inspection, are arranged on the trays in a more closely spaced-out state. The reduction in the distance between containers after the visual inspection enables effective visual inspection and, at the same time, also provides space-saving and compact forward transport of the inspected containers.

[0034] According to a further embodiment of the present invention, the inspection unit is adapted to shift the tray relative to the tube assembly after a first filling operation, and in a second filling operation, to place the containers between the containers placed during the first filling operation. The step of shifting the tray between a first filling operation in which the containers fall onto the tray through the tube assembly and a second filling operation in which the containers fall onto the tray through the tube assembly allows for a more compact arrangement of the containers on the tray. In this embodiment, the tray filling may be carried out in multiple filling operations, e.g., two, three, four, or more filling operations. The number of filling operations can vary depending on the size of the tray. An essential aspect of this embodiment is that the tray is shifted between two subsequent filling operations in order to make optimal use of the free space between previously placed containers.

[0035] According to a further embodiment of the present invention, the inspection unit comprises a waste device configured to isolate containers based on the inspection results, the waste device being operably coupled to a processing unit. Containers that do not meet quality requirements may be removed.

[0036] According to a further embodiment of the present invention, the inspection unit comprises one or more further camera inspection units configured to inspect the inner surface and / or edge division of the container opening. For example, one further camera inspection unit comprising one or more camera units may be configured to inspect the inner surface of the container, e.g., the inner bottom surface and the inner sidewall surface, and another further camera inspection unit comprising one or more camera units may be configured to inspect the edge division (i.e., the retaining edge) at the container opening of the container. According to a further embodiment of the present invention, one further camera inspection unit may provide both functions, i.e., be configured to inspect the inner surface and / or edge division of the container opening. One or more further camera inspection units are operably coupled to a processing unit for evaluation of scanned containers. A disposal device may remove a container from its process if the container fails inspection by the camera inspection unit.

[0037] The present invention also relates to a method for determining the quality of containers within a production line. All aspects described herein with respect to inspection units can be implemented within the scope of this method. In particular, a method for determining the quality of a container includes the steps of: transporting the container using a transport unit through a visual inspection unit comprising multiple camera units that define a visual inspection area in which the container is inspected by multiple camera units; capturing an image of each container from different fields of view in the visual inspection area by different camera units of the multiple camera units as the container is transported through the visual inspection area, wherein the transport unit and the multiple camera units are coordinated so that each of the multiple camera units simultaneously captures multiple containers in the image, and the image comprises multiple image portions, the image portions comprising images of each of the multiple containers' outer surface portions from different fields of view, the image portions captured by the multiple camera units comprising images of each of the multiple containers' outer side surface portions and outer bottom surface portions, and the sum of the images of the outer side surface portions covering the entire outer side surface of the container; and processing the captured image portions for each of the multiple containers using a processing unit operably coupled to the multiple camera units, and determining an inspection result using the processing unit, the step of determining an inspection result comprising comparing image parameters with predetermined parameters.

[0038] According to a further embodiment of the present invention, the method includes the step of removing battery containers that do not meet predetermined quality requirements from the production line.

[0039] According to a further embodiment of the present invention, images of individual containers are simultaneously captured from different viewing angles by different camera units within a visual inspection unit.

[0040] According to a further embodiment of the present invention, the processing unit processes multiple images of the container from different camera units. According to a further embodiment of the present invention, each container is visually inspected by at least three camera units.

[0041] According to a further embodiment of the present invention, for each container, at least nine image portions, each containing an image of the outer surface portion of the container from a different viewing angle, are processed for evaluation.

[0042] According to a further embodiment of the present invention, a stitched image is generated for each container based on the image portion, and the parameters of the resulting stitched image are compared with a predetermined set of parameters.

[0043] According to a further embodiment of the present invention, each container is visually inspected by at least three camera units.

[0044] According to a further embodiment of the present invention, the visual inspection of the container is performed during the continuous transport movement of the container through a visual inspection area.

[0045] According to a further embodiment of the present invention, the containers are transported through a visual inspection area in a grid arrangement. In one embodiment, the containers are transported in a grid arrangement through a visual inspection area in a suspended manner.

[0046] According to a further embodiment of the present invention, the method further includes the steps of transporting a container through one or more additional camera inspection units configured to inspect the inner surface of the container and / or the edge division of the opening of the container, and passing images of the container captured by one or more additional camera inspection units to a processing unit and determining the inspection results. The step of determining the inspection results may include comparing image parameters with predetermined parameters. The present invention provides, for example, the following: (Item 1) An inspection unit (1) for a container (11), in particular for a metal container used in a fixed-dose inhaler or for the manufacture of a battery, A visual inspection unit (9) comprising multiple camera units (20) that define a visual inspection area, wherein the container (11) is visually inspected by the multiple camera units (20) within the visual inspection area, and the visual inspection unit (9), A transport unit (8) for transporting the container (11) through the aforementioned visual inspection area, The transport unit (8) and the plurality of camera units (20) are coordinated so that images of individual containers (11) can be captured within the visual inspection area by different camera units of the plurality of camera units (20) from different field of view angles. The transport unit (8) and the plurality of camera units (20) are coordinated so that each of the plurality of camera units (20) simultaneously captures a plurality of containers (11) in an image, and the image includes a plurality of image portions (24), and each image portion (24) includes images of the outer surface portion of each of the plurality of containers (11) from different viewing angles. The image portion (24) captured by the plurality of camera units (20) includes images of the outer side surface portion (22) and the outer bottom surface portion (19) of each of the plurality of containers (11), and the sum of the images of the outer side surface portion (22) covers the entire outer side surface of the container (11). Transport unit (8), A processing unit operably coupled to the plurality of camera units (20), wherein the processing unit is configured to process the captured image portion (24) with respect to each of the plurality of containers (11) and to determine the inspection result, and determining the inspection result includes comparing image parameters with predetermined parameters, and the processing unit An inspection unit (1) equipped with the following. (Item 2) The inspection unit according to item 1, wherein the transport unit (8) and the plurality of camera units (20) are coordinated so that images of the individual containers (11) can be captured by different camera units from different fields of view at the same time within the visual inspection area. (Item 3) The inspection unit according to item 1 or 2, wherein the processing unit is adapted to process multiple images of a container (11) from different camera units (20). (Item 4) The inspection unit according to any of the above items, wherein the processing unit is configured to process at least nine image portions (24) for each container (11), each containing images of the outer surface portions (19, 22) of the container (11) from different viewing angles. (Item 5) The inspection unit according to any of the items, wherein the processing unit is configured to generate a stitched image of each container (11) based on the image portion (24), and the parameters of the resulting stitched image are compared by the processing unit to a predetermined set of parameters. (Item 6) The inspection unit according to any of the above items, wherein the visual inspection unit (9) is adapted to inspect each container (11) by processing images captured by at least three camera units (20). (Item 7) The transport unit (8) is an inspection unit according to any of the above items, which is adapted to transport the container (11) through the visual inspection area in continuous movement. (Item 8) The inspection unit according to any of the above items, wherein the camera units (20) are arranged in an array configuration (21) such that adjacent camera units (20) are aligned with each other along an axis perpendicular to the direction of transport movement (18) of the transport unit (8). (Item 9) The transport unit (8) is an inspection unit according to any of the above items, which is adapted to transport the container (11) through the visual inspection area in an array or matrix arrangement. (Item 10) The camera unit (20) is an inspection unit according to any of the above items, located below the path of motion of the transport unit (8). (Item 11) The transport unit (8) further comprises a tube assembly (12) with a plurality of tubes (23) and trays (14), wherein, after the visual inspection, the transport unit (8) is adapted to transport the containers (11) into the tubes (23) in such a manner that each tube (23) receives one container (11). The tube (23) is adapted to guide the container onto the tray (14) by gravity, and the tube (23) is at least partially inclined in the direction of fall such that the distance between adjacent containers (11) on the tray (14) is shorter than that on the transport unit (8). The inspection unit described in any of the above items. (Item 12) The inspection unit according to item 11, wherein the inspection unit is adapted to shift the tray (14) relative to the tube assembly (12) after a first filling operation, and to place the container (11) between the containers placed on the tray (14) during the first filling operation during a second filling operation. (Item 13) The inspection unit according to any of the above items, further comprising one or more additional camera inspection units configured to inspect the inner surface of the container and / or the edge division of the opening of the container. (Item 14) A method for determining the quality of a container (11), in particular a metal container used for the manufacture of a fixed-dose inhaler or battery, within a production line, wherein the method is: The container (11) is transported using a transport unit (8) through a visual inspection unit (9) equipped with multiple camera units (20) that define a visual inspection area, wherein the container (11) is inspected by the camera units (20) within the visual inspection area. When the container (11) is transported through the visual inspection area, the visual inspection involves capturing images of each container (11) from different fields of view by different camera units of the plurality of camera units (20), wherein the transport unit (8) and the plurality of camera units (20) are coordinated so that each of the plurality of camera units (20) simultaneously captures a plurality of containers (11) in the image, and the image includes a plurality of image portions, each image portion including images of the outer surface portion of each of the plurality of containers (11) from different fields of view. The image portion captured by the plurality of camera units (20) includes images of the outer side surface portion (22) and outer bottom surface portion (19) of each of the plurality of containers (11), and the sum of the images of the outer side surface portion (22) covers the entire outer side surface of the container (11). The process involves using a processing unit operably coupled to the plurality of camera units (20) to process the captured image portion for each of the plurality of containers (11), and determining the inspection result using the processing unit, wherein determining the inspection result includes comparing image parameters with predetermined parameters. Methods that include... (Item 15) The method according to item 14, further comprising generating a stitched image of each container (11) based on the image portion, and using the processing unit to compare the parameters of the resulting stitched image with a predetermined set of parameters. (Item 16) The method described in item 14 or 15, which includes the step of disposing of containers (11) that do not meet quality requirements. (Item 17) The method further involves transporting the container through one or more additional camera inspection units configured to inspect the inner surface of the container and / or the edge division of the opening of the container. The image of the container captured by the aforementioned one or more additional camera inspection units is passed to a processing unit to determine the inspection result. The method described in any of items 14-16, including the method described in any of items 14-16. [Brief explanation of the drawing]

[0047] The present invention will be described herein with reference to exemplary embodiments shown in the figures.

[0048] [Figure 1] Figure 1 shows an isometric view of an inspection unit according to one embodiment of the present invention. [Figure 2] Figure 2 shows a top view of the inspection unit shown in Figure 1. [Figure 3] Figure 3 schematically shows the details of the inspection unit in Figure 1. [Figure 4] Figure 4 schematically shows the details of the inspection unit in Figure 1. [Figure 5] Figure 5 schematically shows the field of view of the camera unit of the inspection unit shown in Figure 1. [Figure 6] Figure 6 shows a detailed side view of the inspection unit shown in Figure 1. [Modes for carrying out the invention]

[0049] Figure 1 This shows an isometric view of inspection unit 1 for a cylindrical metal container for battery manufacturing, according to a first embodiment of the present invention. Inspection unit 1 is integrated into a production line for battery containers.

[0050] The inspection unit 1 comprises several stations, namely an input station 2 in which battery containers on a first tray 3 are placed on a conveyor line 4. The first tray 3 with the containers then passes through an initial camera inspection unit 5 to detect any initial damage to the containers and inspect the fastening openings.

[0051] After the initial camera inspection unit 5, the container is then moved to the collection station 6. If the initial inspection requirements are not met, the first tray 3 passes through the collection station 6 and proceeds to the removal area 7 where the first tray 3 is removed from the process.

[0052] If the first inspection requirement is met, a transport unit 8, in the form of a robotic arm, transports the containers through a visual inspection unit 9, in which the outer side surfaces (i.e., outer sidewall surfaces) and outer bottom surfaces of the containers are visually inspected to determine the quality of the containers. The robotic arm 8 includes a plate-shaped gripping unit 10. The gripping unit 10 comprises a plurality of individual grippers, each adapted to grip a single container on a first tray 3. Using the grippers, the containers on the first tray 3 are lifted off the first tray 3. Once the containers 11 are lifted off the first tray 3, they are guided through the visual inspection unit 9 in a manner in which they are suspended from the gripping unit 10 for visual inspection. In this process, the outer bottom surface of the containers 11 is oriented downward.

[0053] After passing through the visual inspection unit 9 and the gripping unit 10, the robot arm 8 moves the gripping unit 10, along with the container 11 suspended downward from the gripping unit 10, across the pipe assembly 12. Thereupon, the container 11 is lowered into the opening 13 of the pipe in the pipe assembly 12 that is open downwards. The container 11 passes downwards through the pipe onto a second tray 14 that has been previously moved beneath the pipe assembly 12 on the conveyor line 15.

[0054] Once the second tray 14 is filled with containers 11 with their container openings facing upwards, the second tray 14 passes through a final camera inspection unit 16, which uses a camera mounted inside to visually inspect the inside of the containers and / or the fastening openings or edges of the container openings.

[0055] After passing through the final camera inspection unit 16, the trays pass through a rejection unit 17, which removes containers that fail to meet the quality requirements of the visual inspection unit or the final camera inspection unit from the second tray 14 and thus from the production process.

[0056] Figure 2 The diagram shows a top view of the inspection unit 1. Starting from the collection station 6, the containers are transported through the visual inspection unit 9 while suspended from the gripping unit 10 using the transport unit 8. In doing so, the containers are guided through camera units, which are arranged within the visual inspection unit 9 below the path of movement of the gripping unit 10. The camera units capture images of the containers suspended downwards from below for visual inspection. In this process, the camera units take different images of each container, and a processing unit operably coupled to the camera units compares the image data with predetermined parameters. Containers whose images do not meet the criteria are marked as rejected items, for example, using the rejection unit 17, and removed from the production process in further stages. After passing through the camera units, the containers are lowered into the tube assembly 12 as described above.

[0057] Figure 3 This diagram illustrates the gripping unit 10 as it is passed through the visual inspection unit along the transport direction 18 by the transport unit, i.e., the robot arm. The container 11 is transported in a suspended manner, i.e., the container 11 is suspended downward from the bottom of the gripping unit 10. The outer bottom surface 19 of the container 11, i.e., the closed end of the container 11, is oriented downward.

[0058] In the visual inspection unit, multiple camera units 20 are arranged in an array configuration 21 such that adjacent camera units 20 are aligned with each other along an axis perpendicular to the direction of transport movement of the transport unit, i.e., the transport direction 18. The camera units 20 are oriented upward and capture images of the container array from below. During the visual inspection, the gripping unit 10 continuously passes through the camera units 20, i.e., every single container passes through the array 21 of camera units.

[0059] Figure 4 The diagram in the top view schematically illustrates how the gripping unit 10 is guided across the array 21 of camera units (divided here into camera units 20A-20E) in the transport direction 18. The camera units 20A-20E are arranged in series and perpendicular to the transport direction 18. The camera units 20A-20E define a visual inspection area in which the container 11 (marked here as containers 11A-11I) is visually inspected.

[0060] The containers 11 are arranged on the gripping unit 10 in a grid or matrix arrangement. The gripping unit 10 moves across the array 21 of camera units at a certain distance from the camera units. In the embodiment of Figure 4, the number of containers n in a row, i.e., in the direction lateral to the transport direction 18, is 3, while the number of camera units m for inspecting three containers in a row is 5. This ratio is based on the equation m = n + 2, which proves to be favorable with respect to arrays and matrix arrangements of containers.

[0061] The arrangement of the camera unit 20 and the container 11 on the gripping unit 10 is coordinated in such a way that images of individual containers can be captured within the visual inspection area by different camera units from different field of view angles, in other words, from different viewpoints. This is illustrated in Figure 5.

[0062] Figure 5 This illustrates the field of view of the camera unit 20C in Figure 4, viewed from directly below the gripping unit.

[0063] Camera unit 20C (marked by a dashed circle) captures images of the nine containers 11A-11I on the gripping unit 10 within its field of view at the same time, thereby positioning the central container 11E directly above camera unit 20C with its outer bottom surface 19 visible. In the same manner, container 11B is positioned directly above camera unit 20B (the relative position of camera unit 20B is indicated by a dashed circle), meaning that camera unit 20B has a direct view of the outer bottom surface of container 11B. In the same manner, container 11H is positioned directly above camera unit 20D (the relative position of camera unit 20D is indicated by a dashed circle), meaning that camera unit 20D has a direct view of the outer bottom surface of container 11H.

[0064] Camera units 20B and 20D have the same field of view size as camera unit 20C. This means that adjacent camera units in the array of camera units have overlapping image areas. As a result, images of individual containers can be captured simultaneously by different camera units from different field of view angles within the visual inspection area. Containers 11A-11I are within the field of view of camera unit 20C, while containers 11A, 11B, 11C, 11D, 11E, and 11F are also within the field of view of camera unit 20B. Similarly, containers 11D, 11E, 11F, 11G, 11H, and 11I are also within the field of view of camera unit 20D.

[0065] This means that multiple camera units can simultaneously capture multiple containers 11 in their images. For example, an image containing containers 11A, 11B, 11C, 11D, 11E, and 11F can be simultaneously captured by camera units 20B and 20C, and an image containing containers 11D, 11E, 11F, 11G, 11H, and 11I can be simultaneously captured by camera units 20C and 20D. Furthermore, containers 11D, 11E, and 11F are each within the field of view of camera units 20B, 20C, and 20D. In the same manner, containers 11A, 11B, and 11F are each within the field of view of camera units 20A, 20B, and 20C (see Figure 4). In the same manner, containers 11G, 11G, and 11I are each within the field of view of camera units 20C, 20D, and 20E (see Figure 4).

[0066] As shown in Figure 5, the image captured by the camera unit 20C includes multiple image portions 24, that is, the image captured by the camera unit 20C may be divided into image portions 24 (the division of the image into image portions is indicated by dashed lines 25), such that each image portion 24 includes an image of the outer surface portion of the container. As is evident from Figure 5, the image portion of the image captured by the camera unit 20C includes images of the outer side surface portions 22 of containers 11A, 11B, 11C, 11D, 11F, 11G, 11H, and 11I, and the outer bottom surface portion 19 of container 11E. In a similar manner, the image portion of the image captured by the camera unit 20B in the state shown in Figure 5 includes images of the outer side surface portions 22 of containers 11A, 11C, 11D, 11E, and 11F, and the outer bottom surface portion 19 of container 11B. In a similar configuration, the image portion of the image captured by the camera unit 20D in the state shown in Figure 5 includes images of the outer side surface portions 22 of containers 11D, 11E, 11F, 11G, and 11I, and the outer bottom surface portion 19 of container 11H.

[0067] As the gripping unit 10 moves in the transport direction 18, the container 11F moves relative to the camera unit 20C to the position of container 11E shown in Figure 5, such that the outer bottom surface portion of container 11F is directly above the camera unit 20C, i.e., at the position of container 11E in Figure 5. Container 11E is then at the position of container 11D. Further transport movement of the container in the transport direction 18 moves container 11F to the position of container 11D in Figure 5. Thus, the camera unit 20C can capture each of containers 11D, 11E, and 11F at three different positions, i.e., from three different viewpoints.

[0068] Since the rows of containers 11D, 11E, and 11F are also within the field of view of camera unit 20B, these three containers are also captured by camera unit 20B from three different angles of view during transport motion.

[0069] Furthermore, since the rows of containers 11D, 11E, and 11F are also within the field of view of camera unit 20D, these three containers are also captured by camera unit 20D from three different angles of view during transport motion.

[0070] This means that for each of the containers 11D, 11E, and 11F, the camera units 20B, 20C, and 20D may provide a total of nine images, each image including an image portion with images of the respective outer surface portions of the containers 11D, 11E, and 11F from different viewpoints. In detail, the image portions provided by the camera units 20B, 20C, and 20D include images of the outer bottom surface portions and outer side surface portions of the containers 11D, 11E, and 11F, and the sum of the images of the outer side surface portions covers the entire outer side surface of the individual containers.

[0071] In a similar configuration, the images provided by camera units 20C, 20D, and 20E include nine images, each comprising an image portion containing images of the outer side surface portions and outer bottom surface portions of containers 11G, 11H, and 11I, the sum of which images of the outer side surface portions cover the entire outer side surface of each of containers 11G, 11H, and 11I.

[0072] In a similar configuration, the images provided by camera units 20A, 20B, and 20C comprise nine images, each including an image portion containing images of the outer side surface portions and outer bottom surface portions of containers 11A, 11B, and 11C, the sum of which images of the outer side surface portions cover the entire outer side surface of each of the containers 11A, 11B, and 11C.

[0073] Images captured by the camera unit are transferred to a processing unit, where they are processed. The processing unit processes a single image, isolating containers within the image. For example, the processing unit subdivides the image into several image portions and then assigns the image portions to the corresponding containers. The processing unit then processes the image portions for each container for evaluation. In the embodiment described, nine image portions are processed for each container, each representing the container from a different viewpoint. For each container, the processing unit generates a stitched image based on the image portions, covering the entire outer side surface and outer bottom surface of the container. The parameters of the resulting stitched image are compared by the processing unit to a predetermined set of parameters, such as default values ​​for determining the quality of the container's surface and shape. For example, parameters such as grayscale values ​​or contrast thresholds in predetermined locations may be assigned to the stitched image, respectively. The values ​​are compared to stored reference values. The processing unit can thereby identify visual differences and detect visual material defects such as scratches or equivalents.

[0074] Figure 6The diagram shows the tube assembly 12 of the inspection unit 1. The tube assembly 12 includes a plurality of tubes 23, the tubes whose openings 13 are oriented upward to receive containers from the transport unit.

[0075] After the visual inspection of the containers in the visual inspection unit is completed, the containers are lowered into the tube array 12, with each tube opening 13 receiving one container, and the containers sliding downwards by gravity onto the empty second tray 14 via the tubes 23. As is evident from Figure 6, the tubes partially tilt in the direction of descent so that the distance between adjacent containers becomes shorter, the containers move closer together as they descend, and they lean against the second tray 14 in a closer-to-each-other-together position.

[0076] When the second tray 14 is filled with containers in the first filling operation, that is, when the previously empty second tray 14 receives containers, the inspection unit shifts the second tray 14 horizontally relative to the tube assembly 12. When the transport unit transports another set of containers through the visual inspection unit and lowers the containers into the tubes in the second filling operation of the second tray 14, these containers fall between the containers placed on the second tray 14 in the first filling operation. A compact and effective arrangement of containers on the second tray 14 is achieved.

[0077] The filled second tray 14 then passes through the final camera inspection unit. Containers that do not meet the quality requirements of the visual inspection within the visual inspection unit or within the final camera inspection unit are then sorted and removed by the rejection unit 17.

[0078] Reference number 1 Inspection Unit 2 Input Stations 3. First tray 4 Conveyor Line 5. Initial camera examination 6 Collection Stations 7 Removal Area 8 Conveyor Units 9. Visual Examination Unit 10 Plate-shaped gripping unit 11 Container 12 Pipe Assembly 13 Pipe opening 14. Second tray 15 Conveyor Line 16. Final camera inspection unit 17 Rejected Units 18 Conveying direction 19. Outer bottom surface of the container 20 Camera Units 21 Array of camera units 22 Side surface portion of the container 23 tube 24 Image section 25 Image division lines

Claims

1. An inspection unit (1) for a container (11), A visual inspection unit (9) comprising a plurality of camera units (20) that define a visual inspection area, wherein the container (11) is visually inspected by the plurality of camera units (20) within the visual inspection area, and the visual inspection unit (9), A transport unit (8) for transporting the container (11) through the visual inspection area, The transport unit (8) and the plurality of camera units (20) are coordinated so that images of individual containers (11) can be captured within the visual inspection area by different camera units of the plurality of camera units (20) from different field of view angles. The transport unit (8) and the plurality of camera units (20) are coordinated so that each of the plurality of camera units (20) simultaneously captures a plurality of containers (11) in the image, and the image includes a plurality of image portions (24), and the image portions (24) include images of the outer surface portions of each of the plurality of containers (11) from different viewing angles. The image portion (24) captured by the plurality of camera units (20) includes images of the outer side surface portion (22) and outer bottom surface portion (19) of each of the plurality of containers (11), and the sum of the images of the outer side surface portion (22) covers the entire outer side surface of the container (11). Transport unit (8), A processing unit operably coupled to the plurality of camera units (20), wherein the processing unit is configured to process the captured image portion (24) with respect to each of the plurality of containers (11) and to determine the inspection result, and determining the inspection result includes comparing image parameters with predetermined parameters, A tube assembly (12) comprising a plurality of tubes (23) and trays (14), wherein the transport unit (8) is adapted to transport the containers (11) into the tubes (23) in such a manner that each tube (23) receives one container (11) after visual inspection by the plurality of camera units (20), The tube (23) is adapted to guide the container onto the tray (14) by gravity, and the tube (23) is at least partially inclined in the direction of fall such that the distance between adjacent containers (11) on the tray (14) is shorter than that on the transport unit (8), and the tube assembly (12) An inspection unit (1) equipped with the following:

2. The inspection unit according to claim 1, wherein the transport unit (8) and the plurality of camera units (20) are coordinated such that images of the individual containers (11) can be captured by different camera units from different fields of view at the same time within the visual inspection area.

3. The inspection unit according to claim 1 or 2, wherein the processing unit is adapted to process multiple images of a container (11) from different camera units (20).

4. The inspection unit according to claim 1 or 2, wherein the processing unit is configured to process at least nine image portions (24) for each container (11), each containing images of the outer surface portions (19, 22) of the container (11) from different viewing angles.

5. The inspection unit according to claim 1 or 2, wherein the processing unit is configured to generate a stitched image of each container (11) based on the image portion (24), and the parameters of the stitched image are compared by the processing unit with a predetermined set of parameters.

6. The inspection unit according to claim 1 or 2, wherein the visual inspection unit (9) is adapted to inspect each container (11) by processing images captured by at least three camera units (20).

7. The inspection unit according to claim 1 or 2, wherein the transport unit (8) is adapted to transport the container (11) through the visual inspection area in continuous movement.

8. The inspection unit according to claim 1 or 2, wherein the camera units (20) are arranged in an array configuration (21) such that adjacent camera units (20) are aligned with each other along an axis perpendicular to the direction of transport movement (18) of the transport unit (8).

9. The inspection unit according to claim 1 or 2, wherein the transport unit (8) is adapted to transport the containers (11) through the visual inspection area in an array or matrix arrangement.

10. The inspection unit according to claim 1 or 2, wherein the camera unit (20) is located below the path of motion of the transport unit (8).

11. The inspection unit according to claim 10, wherein the inspection unit is adapted to shift the tray (14) relative to the pipe assembly (12) after a first filling operation, and to place the container (11) between the containers placed on the tray (14) during the first filling operation during a second filling operation.

12. The inspection unit according to claim 1 or 2, further comprising one or more additional camera inspection units configured to inspect the inner surface of the container and / or the edge division of the opening of the container.

13. A method for determining the quality of a container (11) within a production line, wherein the method is The container (11) is transported using a transport unit (8) through a visual inspection unit (9) equipped with multiple camera units (20) that define a visual inspection area, and within the visual inspection area, the container (11) is visually inspected by the camera units (20). When the containers (11) are transported through the visual inspection area, images of each container (11) are captured from different fields of view by different camera units of the plurality of camera units (20) within the visual inspection area, wherein the transport unit (8) and the plurality of camera units (20) are coordinated so that each of the plurality of camera units (20) simultaneously captures a plurality of containers (11) in the image, and the image includes a plurality of image portions, and the image portions include images of the outer surface portions of each of the plurality of containers (11) from different fields of view. The image portion captured by the plurality of camera units (20) includes images of the outer side surface portion (22) and outer bottom surface portion (19) of each of the plurality of containers (11), and the sum of the images of the outer side surface portion (22) covers the entire outer side surface of the container (11). The process involves using a processing unit operably coupled to the plurality of camera units (20) to process the captured image portion for each of the plurality of containers (11), and determining the inspection result using the processing unit, wherein determining the inspection result includes comparing image parameters with predetermined parameters. The transport unit (8) transports the container (11) to the tube assembly (12), wherein the tube assembly (12) comprises a plurality of tubes (23) and a tray (14), and the transport unit (8) transports the container (11) into the tubes (23) in such a manner that each of the tubes (23) receives one container (11) after visual inspection by the plurality of camera units (20). The tube (23) guides the container onto the tray (14) by gravity, and the tube (23) is at least partially inclined in the direction of fall such that the distance between adjacent containers (11) on the tray (14) is shorter than that on the transport unit (8). Methods that include...

14. The method according to claim 13, further comprising generating a stitched image of each container (11) based on the image portion, and using the processing unit to compare the parameters of the generated stitched image with a predetermined set of parameters.

15. The method according to claim 13 or 14, further comprising the step of discarding containers (11) that do not meet quality requirements.

16. The method further involves transporting the container through one or more additional camera inspection units configured to inspect the inner surface of the container and / or the edge division of the opening of the container, The image of the container captured by the aforementioned one or more additional camera inspection units is passed to a processing unit to determine the inspection result. The method according to claim 13 or 14, including the method described in claim 13 or 14.

17. The inspection unit according to claim 1, wherein the inspection unit is adapted for inspecting metal containers used for the manufacture of fixed-dose inhalers or batteries.

Images