Blister Pocket Sidewall Inspection With Optical Path Conversion
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Solution Overview
Problem
Existing container inspection devices face challenges in efficiently inspecting multiple containers for defects on side walls with varying accuracy and precision, particularly due to limitations in imaging technology and optical path conversion, leading to inconsistencies in determining the presence and location of flaws or foreign substances.
Innovation Solution
A container inspection device equipped with an irradiation unit, optical path conversion sheets, and an imaging optical system that converts light paths from multiple side wall areas onto an imaging element, allowing simultaneous inspection of multiple containers and enhancing accuracy by maintaining consistent image sizes and shapes, thereby improving precision in defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If a wide angle lens is placed immediately above the opening of a container to inspect side wall portions, then the inspection capability for side walls is achieved, but the number of containers that can be imaged simultaneously is limited to only one
Solution Approach 1:
The inspection system divides the field of view into multiple regions by placing multiple imaging elements (cameras) at different positions. Each camera is responsible for inspecting specific side wall portions of containers, enabling parallel inspection of multiple containers simultaneously while maintaining comprehensive coverage of side wall defects
Solution Approach 2:
The system transitions from a single-point inspection approach to a multi-dimensional inspection arrangement by positioning cameras at different locations and angles. This spatial distribution allows simultaneous capture of multiple containers' side wall portions, dramatically improving inspection throughput without compromising detection capability
2Productivity
If cameras are placed to take images of side wall portions from obliquely above the container to enable simultaneous imaging of multiple containers, then inspection efficiency is improved, but the size of the side wall portion images varies by container location causing variation in inspection accuracy
Solution Approach 1:
The system employs multiple imaging elements with different optical characteristics positioned at specific locations to capture side wall portions. Each imaging element is optimized for its specific viewing angle and distance, ensuring that containers at different positions receive appropriate imaging quality. The determination unit then processes these differentiated images to maintain consistent inspection accuracy across all container locations
Solution Approach 2:
The determination unit analyzes image data from multiple cameras and compensates for variations in image size and quality based on container position. By comparing images against predetermined criteria and adjusting evaluation parameters according to the specific camera-viewpoint relationship, the system maintains uniform inspection accuracy despite the varying geometric conditions introduced by multi-position imaging
3Productivity
If a prism sheet is used to take images of container side walls, then simultaneous imaging of multiple containers is enabled, but the image data becomes blurred making it difficult to determine the presence or position of defects with high accuracy
Solution Approach 1:
The system replaces the prism sheet intermediary with direct optical paths from multiple cameras to the container side walls. By eliminating the light-collecting sheet that causes blurring, the system achieves sharp, high-contrast images while maintaining the ability to simultaneously image multiple containers through strategic camera placement and optical path design
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enables high-accuracy and precise detection of defects on container side walls, improving inspection efficiency and reducing variations in accuracy by ensuring clear contours and shapes of defects are captured in the image data.
Implementation Method 1
an optical path conversion sheet configured to convert an optical path of light that is radiated from the irradiation unit and that is reflected from or transmitted through a one side wall area into an optical path along a direction of an optical axis
Implementation Method 2
an imaging optical system configured to form an image of the light having the optical path converted by the optical path conversion sheet, onto the imaging element
Implementation Method 3
light that is radiated from the irradiation unit and that is reflected from or transmitted through a one side wall area
Implementation Method 4
light that is radiated from the irradiation unit and that is reflected from or transmitted through a one side wall area
Data Source
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AI summary
There is provided a container inspection device or the like configured to, for example, determine the presence or the absence of any defective part in a side wall portion with the high accuracy, while improving the inspection efficiency and suppressing a variation in inspection accuracy. A container inspection device 21 comprises optical path conversion sheets 52a to 52d, each being configured to convert an optical path of light reflected from or transmitted through a one side wall area that is continuous in a circumferential direction of a side wall portion of a pocket portion; an imaging optical system 56 configured to form an image of lights having optical paths converted by the optical path conversion sheets 52a to 52d, on an imaging element 54c; and an image processing device 55 configured to perform defective/ non-defective determination of the side wall portion, based on image data obtained from the light imaged on the imaging element 54c. Each of the plurality of optical path conversion sheets 52a to 52d is provided to correspond to a different one side wall area and is configured to convert an optical path of light reflected from or transmitted through the corresponding one side wall area into an optical path along a direction of an optical axis of the imaging optical system 56. A plurality of the one side wall areas corresponding to the respective optical path conversion sheets 52a to 52d cover the entire circumference of the side wall portion.