DESCRIPTION Title
INSPECTION DEVICE AND PTP PACKAGING MACHINE
Technical Field
[0001] The present disclosure relates to an inspection device used to inspect a PTP sheet or a portion that eventually forms a PTP sheet, as well as to a PTP packaging machine including the inspection device.
Background
[0002] The PTP sheet includes a container film that has pocket portions filled with contents such as tablets or capsules and a cover film that is mounted to the container film such as to seal openings of the pocket portions. [0003] The PTP sheet is manufactured by a PTP packaging machine. The PTP packaging machine includes a pocket portion forming unit configured to form pocket portions in a strip-like container film; a filling unit configured to fill contents into the pocket portions; a sealing unit configured to mount a cover film to the container film and thereby obtain a strip-like PTP film; and a sheet punching unit configured to punch out the PTP film in the unit of sheets and thereby provide PTP sheets.
[0004] In a manufacturing process of the PTP sheet, an inspection device is provided along a conveyance path of the container film. The inspection device conducts an inspection of a predetermined inspection object portion in a PTP sheet or a portion that eventually forms a PTP sheet (as described in, for example, Patent Literature 1). The inspection device includes an irradiator configured to irradiate the inspection object portion with light; an imaging unit configured to take an image of the inspection object portion irradiated with the light; and a quality judgment unit. The quality judgment unit detects the presence or the absence of a defect in the inspection object portion, based on the image taken by the imaging unit, so as to judge the inspection object portion as non-defective or as defective. More specifically, the quality judgment unit uses preset luminance threshold value to detect a defect with regard to the appearance abnormality of a content or a sheet portion, for example, break of the content (for example, peel-off of the surface of the content), adhesion of a foreign substance to the content, or quality of sealing in the sheet portion.

[0005] Pant Literature 1: JP 2001-33390A
Summary V roblem
[006 don of whether an inspection by the inspection device is normally conducted, i.e., verification of whether the set luminance threshold value is appropriate, is performed, for example, prior to operation of the inspection device. A general procedure of such verification creates a plurality of sheets expected to be judged as defective by the quality judgment unit (defective sheets) according to the types of defects or the like, feeds supply defective sheets to the inspection device and determines whether
g an:a=d—xmp n p f foreign of the
pvd h an^bJa^n h PT h -et, there is a need
not present B at hadn g into account the circumstances described above, an object of the present disclosure is to provide an inspection device that is
verification, as well as a PTP packaging machine. the convenience
ZT fiem ing describes each of various aspects provided

" n npn a is provided an inspection device confi n ed to
process of the PTP sheet configured such that a content is contained in a pocket portion formed in a container film and a cover film is bonded to the container film to close the pocket portion. The inspection device comp n ses
with p adia determind gh
inspection object portion irradiated with the light emitted from the irradiator; a quality judgment unit configured to detect presence or absence of a defect in the inspection object portion from the image taken by the imaging unit by using a predetermined luminance threshold value and thereby judge the inspection object portion as no g defective or defective; a
toh umnan h config v ration of the above aspect a enables verification of the

inspection object. This configuration enhances the convenience of content. Such a defective image may be an image having a luminance that
threshold values is detectable. This is not capable of verifying whether the
in a non-defective image, the luminance of the defective image is set on the basis of the luminance of the content. In another example, when a defective nn age simulating a foreign substance is placed on a sheet portion in a
v"n whh h umnan t h^vau:^^
luminance that is close to the luminance of the content or the luminance of
luminance ponrtion. Thi

the irradiator may be configured to radiate lights of multiple ma fferent
mpnnZZ££^XZ^may be
of approximately 495 nm to approximately 570 nm).
wavelength component of light. The configuration of the above aspect 2
e n"h u™^
different wavelength components. As a result, this configuration allows for verifying of whether the luminance threshold value is appropriate in
to" p pect 3.'bd abv h d device described in either the aspect 1

portion of the non-defective image where the dark defective image is placed, such as to be lower than the luminance of the portion; and a bright defective
a dark defective of a relatively low luminance and an image indicating a bright defective of a relatively high luminance are set on the basis of the luminance of the portion of the non-defective image where the defective
based on a luminance of a portion of the non-defective image where the
increase the luminance outward from the center. More specifically, the dark defective image has an identical mode with the mode of an image of a foreign substance obtained when the image of the foreign substance is actually
luminance threshold value conforming to the actual inspection.
[0025] Aspect 5. There is provided a PTP packaging machine comprising
the inspection device described in any of the aspects 1 to 4 described above.

pre-sealing inspection unit and a post-sealing inspection unit;
6 7 is a diagram illustrating ma verification image;. virtual rectangle
defect Fg 1 ge placed in a table p a n ^ ^ ^_ ^ a
defect Fg 11 i a whart showing an image providing/ outputting
process; Fig. 12 is a flowchart showing a virtual inspection-relating process;
and Fig. 13 is a flowchart showing a luminance threshold value
verification process.
Sn viw PTP sheet 1 is forme in an approximately rectangular shape
directld a Each pocket a g.ay is comprised of fi A pocket portions 2 that are [0031] The PTP sheet 1 is manufactured by punching sheets from a

strip-shaped PTP film 6 (shown in Fig. 3) that is comprised of the strip-shaped container film 3 and the strip-shaped cover film 4.
wiom n^a m up'll of the strip-shaped con kag r film 3 is wound in a roll
The container film 3 is then laid on an intermittent feed roll 14 provided on a
n m 3 mny1:,^^"as to convey the
the pocket portions 2 is performed during an interval between convey operations of the container film 3 by the intermittent feed roll 14.
20 in this order. The film receiving roll 20 is coupled with a motor rotating at a fixed speed, so as to continuously convey the container film 3 at a fixed speed. The tension roll a 8 is confi Th ed to p n ll the container film 3 to the
h nn tablet fil b ng device 2 gu is provided along the conveyance path of tablets a into the pocket portions . The tablet filling device 21 opens a

^t^ZZr^p-sh a ped cover film 4 is also wound on a roll
" A^Jd most up cTZtwound in the roll form is guided
by a guide roll 24 to a heating roll 25. The heating roll 25 is pressed against
The container film 3 and the cover film 4 pass through between the two rolls 20 and 25 in the heated and pressed contact state, so that the cover film 4 is attached to the container film 3 such as to close the respective pocket portions 2. This series of operations provides the PTP film 6 manufactured such that the tablet 5 is filled in each of the pocket portions 2. [0039] The PTP film 6 fed from the film receiving roll 20 is sequentially laid on a tension roll 27 and an intermittent feed roll 28 in this order. The intermittent feed roll 28 is coupled with a motor rotating in an intermittent manner, so as to convey the PTP film 6 intermittently. The tension roll 27 is configured to pull the PTP film 6 to the state of tension by an elastic force. This con h uration prevents a slack of the PTP film ng due to a difference
[0040] m The PTP ate of tension m the intermittent feed roll 28 is sequentially laid on a tension roll 31 and an intermittent feed roll 32 in this order. The intermittent feed roll 32 is coupled with a motor rotating in an intermittent manner, so as to convey the PTP film 6 intermittently. The
33 serves to form a cutting slit at predetermined positions of the PTP film 6.
The stamping device 34 serves to stamp a mark at predetermined positions
[0042] The PTP film 6 fed from the intermittent feed roll 32 is

sequentially laid on a tens d on roll 35 and a continuous feed roll 36 in this
the PTP fil T m h 6 in the wit of PTP h sheet 1 by the sheet punching device 37 are
conveyed by an extraction conveyor 38 and are once accumulated in a finished product hopper 39. In the case of defective judgment of the PTP sheet 1 by inspection units 52 and 53 desc n bed late, a defective signal is
judged as defective is separately d charged by the defective sheet discharge
punching device 37 is guided by the tension roll 35 and the continuous feed roll 36 and is subsequently led to the cutting device 41. A driven roll is pressed against to be n contact ad h the continuous feed roll 36, so that the
PTP spe she o t« isectin device 51 includes, 53 a e n x d amp veri a pre-sealing

inspection for the presence or the absence of a defect in the tablet 5 or in the
surface side of the tablets 5) after sealing. The post-sealing inspection unit 53 is provided between the film receiving roll 20 and the tension roll 27 and is configured to conduct an inspection for the presence or the absence of a defect in the tablet 5 or in the d p TP film 6 (sheet portion). According to the
dv 60 Each of the inspection units 52 and 53 is pro g a ded h1th a n ghting
the portion of the container film 3 or the PTP film 6 that eventually forms the PTP sheet 1 with predetermined light both from the opening side and from the protruded portion side of the pocket portions 2.
of different wavelength components. According to the embodiment, light of a red (R) color component (light having wavelength of about 620 nm to about 750 nm), light of a blue (B) color component (light having wavelength of
[0052] The pre-sealing inspection unit 52 includes the two lighting

_„ mpnn .h.g„n G„«.„mpnn. Three images of the red (R)
such lights of n fferent wavelength component v This is based on the fact
Z Lt:::^:;:;i: irr; z^Z^z^e
wavelength component of radiating n gh n
One camera 61 is used to take a two-dimensional image of light transmitted
on the opening side of the pocket portions 2.
(PTP film 6). In the pos a sealing inspection u d t 53, the camera 61 is used

[0059] The image memory 63 is configured to store images taken by the image memory 63. The images may be sub amp ed to processing, prior to the
brightness of light caused by the difference in position, since there are

products determined in past inspections, for example, reference values used
PooTP film 6). first tablet luminance threshold value 8x1 is used to identify a bright defect of the tablet 5 that is displayed in a relatively bright mode in an area of the image occupied by the tablet 5. The bright defect of the tablet 5 occurs, for example, when the tablet s a sugar-coated tablet and has a peeled-off sugar-coat. The first tablet luminance threshold value 8x1 is set to be lower than an expected luminance of a bright defect of the tablet 5
rab umnan hhd vau x1 pvd a vausgh
[0064] The second tablet luminance threshold value 5x2 is used to identify a dark defect of the tablet 5 that is displayed in a relatively dark mode in the area of the image occupied by the tablet a The dark defect of
set to be higher than an expected luminance of a dark defect of the tablet 5
set second tablet luminance threshold value 8x2 provides a value 0 for the presence of a foreign substance part and the value 1 for the surface of the
toablet, a resulting binarized image. * value 8y is used to identify a dark
defect of the sheet portion that is displayed in a relatively dark mode in an area of the image occupied by the sheet portion. The dark defect of the

break or cease. The sheet luminance threshold valuey is set to be lower than an expected luminance of a dark defect of the sheet portion obtained in advance but to be higher than the luminance of the surface of the sheet
a foreign substance or a break and a value 1 for the sheet portion. [0066] The luminance threshold value Sx1 is set to be a relatively low value when inspection of a defective part is to be performed strictly, i.e., when there is a demand for re x2 ably detecting a defective part. The
umnan hhdthe pre-sea 2 and nspection u nd t 52 sets the [0070] The camera timing control device 67 is configured to control the

packaging machine 11. An image is taken by the h PTP 61 whenever a input/output x terface 68 is configured to execute va ab s process n
function enables various images and inspection results to be displayed in the
mass processing of a binarized image obtained by the binarization process, and a defect judgment process of determining the presence or the absence of a defective part, based on the number, the area and the position of a mass
p* npn un 2 and t 3^^.acy.^ in the

bnad mag. a. hJ d R].r .«mpn . This providesa plurality of
obtained binarized image to be subjected to a masking process with regard to an area of the pocket portion 2 h1.p ith regard to an area of the sheet portion
then causes the binarized image to be subjected to a mass processing and compares the area of a mass part with a reference value set in advance for area determination, so as to conduct an inspection for the presence or the absence of a defective part in the tablet 5 and in the sheet portion. [0077] The post-sealing inspection unit 53 is configured to conduct an inspection for con nH.mination or non-contammH.non Dy ny forei ab n su 5 stance
.»a du he „h np r th, .h~ ,r .»„bnormali„ i n u h, „»,,ba . A

the luminance threshold values Sx1, 8x2 and Sy are appropriate in each of the inspection units 52 and 53. As shown 55 Fig. 4, the verification device
change over the operation mode of the inspection unit 52 or 53 to the inspection mode or to the verification mode. The operation mode is,
provided in the PTP packaging machine 11.

placed in the verification image VI. In general, however, one defective
g TP film 6) with the camera 61. The radiation conditions of light from the and the like. The non-defective image GI may be obtained by a
[0086] The defective image DG simulates a defect such as a foreign
changed As shown in Fig. 7 (Fig. 7 is an enlarged view of a virtual rectangle VR in Fig. 6), a defective image DG includes a bright defective

foreign substance or cease of the sheet. According to the embodiment, the
portion SP Furthermore, respective non-defective images GI of the red (R) color component, the green (G) color component and the blue (B) color component with defective images DG of the corresponding color components
corresponding to one camera 61 and corresponding to the other camera 61.
verification image VI of the post-sealing inspection unit 53.
[0090] The luminance of the defective image DG is set, on the basis of the
placed in the tablet 5 of the no 5 defective image GI is set, on the basis of the image DG2 (for example, a dark defective image DG2 simulating a foreign
luminance expected as the luminance of the bright defect) and Lx1 denotes a

tablet an where the dark defective image DG2 is to be placed there h , a
lum hr^a L2 of o te dark n defective image DG2
set to the luminance threshold value 5x1 and a relatively high value is set to the luminance threshold value u x2 5 order to conduct a strict au spection of a
Lmax. These luminances Lmax may, however, be different from one another according to, for example, the color of the surface of the tablet 5.
image DG2 is to be placed therein, a lum an ance L3 of the dark defective
of the sheet portion SP. the luminances of defective images DG are set independently according to the lights of the respective wavelength
component the red (R) color component, the green (G) color component and

placed in the non-defective image GI of the red (R) color component
component. In the process of setting the luminance of the defective image DG, the luminance of the defective image DG may be finely adjusted according to the location of the defective image DG, by taking into account that a center part of an imaging region is likely to have a relatively high luminance and an outside part of the imaging region is likely to have a relatively low luminance and that a center part of the tablet 5 is likely to have a relatively high
luminance and an outside part of the tablet 5 is likely to have a relatively low
maid™Th v:a:n mag g—55 aumaa,The
va h SP. The luminance of the defective image DG may g e input directly
may be automatically set to the luminance of the defective image DG.
h pn S^aumaay ^^Z'd or the

h p;er:™and 53 performs an inspectionvrzr-a,n ,
._„„,,.„„„ 52 „„audgmn „u iate, wh» ,n nd i a ividual quality judgment results of the ,„„,«,,,»»w™,hd vau x1 f x2 and i.whn a d „»v mag DG d,d a xp ad,»s „.«.y,
«rumnan;:=vau x1;x2 and y nd,a using the

h l,hd , the th x2 ho».pndng „ 56 d R, that the luminance
zr~n mag V:lts,«",threshold values
check the verification images VI used for verification, based on the displayed
displayed Th lowing describes processes relating to verification of the
luminance threshold values 5x1, 5x2 and 5y described above with reference to flowcharts. The processes relating to verification include an image providing/ outputting process performed in the verification image generator 55, an operation mode changeover and virtual inspection-relating process
verification image generator 55 is described first. The image providing/
53:;;::—::=":—T^~^ ^
[0107] As shown in Fig. 11, the image providing/ outputting process first determines whether the operation mode in each of the inspection units b 2

sr^==i:,_„„.a .n mag V a
set, on the basis of the lu g DG p in a location of a non-defective image GI
inspection units 52 and 53. More specially, it is determined whether the ve m fication images VI of the red (R) color component, the green (G) color
=:ng p=r.mnad::i rz;°;r::, „„«

select process at step S22 and is then terminated. The image selecting
hand h vua n ^^a^:dm at step S21, on the other
inspection-relating process determines that an abnormality occurs in the setting of the operation mode and performs the abnormality process. The abnormality process performed is, for example, a process of notifying that the
^pn=:pm"at step S25, the
quality judgment with regard to the input verification image VI (judgment result information) is output to the verification device 54. The judgment
regarding the type of the verification image VI as described above.

negative determination is made at step S28, i.e, when there is any verification image VI that is not yet input, the virtual inspection-relating
input from the md tion a nits 52 and 53 at step S3 d This det n mad n specifica y , it is det h d d whether each of the d.e v on anits 52 and 53
ha ny bn npu a p S36 dbd a"^rin The stored
[0123] When an affirmative determination is made at ste p S32, the
luminance threshold value verification process proceeds to steP S33 that

the identified luminance threshold values S x1, h x2 and n y are inappropriate. h x2 and 5y (threshold value dete bd abv on results) into the storage device of
be displayed in the above display device.
[0128] As described above, accord x2 to the embodiment, a verification of

constituent material of the sheet portion SP. One possible measure may use a commonly usable defective image, irrespective of the difference in type of
threshold values is detectable. This is not capable of verifying whether the lu P Th that is close to the l_eey f the tablet 5 or the sheet portion

This configuration accordingly allows for verification of whether the are appropriate in detection of a wider range of defects.
configuration allows for verification of the luminance threshold values 8x1, above embodiment but may also be implemented, for example, by
S1"1 t) described be t lo oWthe above embodiment, white light is emitted from the lighting device 60 of the pre-sealing inspection unit 52. More
specifically, the lighting device 60 is configured to simultaneously radiate

by radiation of white light. In this modification, the luminance of the B and
the sheet portion SP in the non-defective image GI corresponding to white
[ md 38] (c) The configurations of the inspection units 52 and 53 may 5 e ^mbdmn a ny ua values 8x1, 8x2 and n y described in
[0140]011 mu th a t ew to t mnan hd vu t types of defects more
b u ct d"
[0141] (e) According to the above embodiment, the inspection device 54 is placed at the same location as the installation location of the PTP packaging

specifically, the verification device 54 may intensively perform inspection of
the luminance threshold values in multiple inspection units placed at
different locations.
[0143] Additionally, a modified configuration may individually provide a
threshold value verification unit of a verification device in each of PTP
packaging machines and may provide a verification image generator of the
verification device separately from the respective PTP packaging machines.
This modified configuration may send required verification images from the
verification image generator to the PTP packaging machines.
[0144] (f) The above embodiment is configured to inspect a portion that
eventually forms the PTP sheet 1 in the manufacturing process of the PTP
sheet 1. A modification may be configured to inspect the PTP sheet 1 as the
final product.
[0145] (g) The above embodiment concretely describes the configuration
for the tablet 5 as the content. The content may, however, be a capsule (for
example, a medical product or a nutrition product)
[0146] (h) According to the above embodiment, the container film 3 is
made of a thermoplastic resin material such as PP or PVC, and the cover film
4 is formed by using aluminum foil or the like as the base material. The
materials of the respective films 3 and 4 are, however, not limited to these
materials but may be other materials.
Reference Signs List
[0147] 1… PTP sheet, 2… pocket portion, 3… container film, 4… cover film, 5… tablet (content), 11… PTP packaging machine, 51… inspection device, 55… verification image generator (verification image generating unit), 56… threshold value verifier (threshold value verifying unit), 60… lighting device (irradiator), 61… camera (imaging unit), 62… processing device (quality judgment unit), DG… defective image, DG1… bright defective image, DG2… dark defective image, GI… non-defective image, VI… verification image

WE CLAIM:
predetermined inspection object portion in a PTP sheet or in a portion that eventually forms the PTP sheet in a manufacturing process of the PTP sheet
pocket portion,
wh pdm gZL* at least the inspection object portion a™;"h d gh h ured to take an mage of da ^^ ***
"^r^^^cS^^^l or absence defect in the inspection object portion from the image taken by the imaging unit by using a predetermined luminance threshold value and thereby judge the inspection object portion as non-defective or defective;
a verification image generating unit configured to generate a
^^nnlength components, and image is set independently according
to the light of each of the wavelength components.
3. The inspection device according to either claim 1 or claim ,
wherein the defective image includes:

a dark defective image having a luminance that is set based on a luminance of a portion of the non-defective image where the dark defective image is placed, such as to be lower than the luminance of the portion; and
a bright defective image having a luminance that is set based on a luminance of a portion of the non-defective image where the bright defective image is placed, such as to be higher than the luminance of the portion.
4. The inspection device according to any one of claims 1 to 3,
wherein the defective image has a luminance that is set based on a
luminance of a portion of the non-defective image where the defective image is placed, such as to be lower than the luminance of the portion and that is set to gradually increase outward from a center thereof.
5. A PTP packaging machine, comprising the inspection device
according to any one of claims 1 to 4.