Patent Description:
A device which can optically inspect a packaging container for a smoking article has hitherto been known (for example, refer to Patent Literature <NUM>). Further prior art can be found in <CIT> relating to a state inspection apparatus for inspecting the glue state of gluing an object and <CIT> relating to a technique for inspecting the state of the location pasted by an apparatus.

However, the device disclosed in Patent Literature <NUM> does not have a function for inspecting a position shift of an adhesive which is applied to a blank, from which a packaging container for a smoking article is constructed, and has a color identical with or similar to the color of the blank.

The present invention has been achieved in view of the above point; and an object of the present invention is to judge a position shift of an adhesive which is applied to a blank and has a color identical with or similar to the color of the blank, for manufacturing a packaging container for a smoking article.

The invention is defined by the independent claims while preferred embodiemnts are defined by the dependent claims. For solving the above problem, a first mode of the present invention is an inspection device for judging a position shift of a test object to be inspected which is arranged on a blank, from which a packaging container for a smoking article can be constructed, and has a color similar to a color of the blank, and the inspection device for the smoking-article packaging container comprises: an illumination unit for illuminating, from a first direction, the blank which includes the test object; an imaging unit for taking an image of the blank including the test object from a second direction that is different from the first direction, and generating image data; and an image processing unit for identifying, based on brightness, a relative position of the test object with respect to the blank in the image data, wherein the image processing unit is constructed to perform: a process for identifying a position of the blank by detecting an edge of the blank in the image data; a process for dynamically setting in the image data a target arrangement area for the test object by using the detected edge of the blank as a position reference; a process for detecting the test object based on the brightness in the image data; a process for identifying relative positions of the detected test object and the target arrangement area; and a process for judging, based on the relative positions, whether the test object is positioned in the target arrangement area on the blank.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode,
wherein the first direction and the second direction are set to have positional relationship that satisfies a condition that a bright part and a dark part are formed on a surface of the test object, that is viewed from a position of the imaging unit, by illumination by the illumination unit.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the first direction and the second direction are set to have positional relationship that satisfies a condition that the surface of the blank is darker than the bright part and brighter than the dark part.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the first direction is substantially parallel to the surface of the blank.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the second direction is substantially vertical to the surface of the blank.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the image processing unit is constructed to identify, in the image data, an image area which has brightness corresponding to at least one of the bright part and the dark part on the surface of the test object, in the process for detecting the test object.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the image processing unit is constructed to set the target arrangement area to be positioned in a position, that is a predetermined distance away from the detected edge of the blank, in the image data, in the process for setting the target arrangement area.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the image processing unit is constructed to perform a process for binarizing the image data, before performing the process for detecting the test object.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the image processing unit is constructed to judge that manufacturing failure has occurred, when at least part of the test object is not positioned in the target arrangement area on the blank.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the image processing unit is constructed to judge that manufacturing failure has occurred, when the test object is not detected in the process for detecting the test object.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the test object is emulsion, sol, or liquid applied to the blank.

Further, a different mode of the present invention comprises the inspection device for the smoking-article packaging container in the above mode, wherein the test object is an adhesive which is applied to the blank for constructing the packaging container from the blank.

Further, a different mode of the present invention is an apparatus for manufacturing a smoking-article packaging container, and the device comprises: the inspection device for the smoking-article packaging container in the above mode; a conveying device for conveying the blank; a supplying device for supplying the test object on the blank; and an assembling device for constructing the packaging container from the blank.

Further, a different mode of the present invention is an inspection method for judging a position shift of a test object to be inspected which is arranged on a blank, from which a packaging container for a smoking article can be constructed, and has a color similar to a color of the blank, and the inspection method for the smoking-article packaging container comprises: a step for illuminating, from a first direction, the blank which includes the test object; a step for taking an image of the blank including the test object from a second direction that is different from the first direction, and generating image data; and a step for identifying, based on brightness, a relative position of the test object with respect to the blank in the image data, wherein the step for identifying comprises: a step for identifying a position of the blank by detecting an edge of the blank in the image data; a step for dynamically setting in the image data a target arrangement area for the test object by using the detected edge of the blank as a position reference; a step for detecting the test object based on the brightness in the image data; a step for identifying relative positions of the detected test object and the target arrangement area; and a step for judging, based on the relative positions, whether the test object is positioned in the target arrangement area on the blank.

According to the present invention, a position shift of an adhesive, which is applied to a blank and has a color identical with or similar to a color of the blank, can be judged and a packaging container for a smoking article can be manufactured.

In the following description, embodiments of the present invention as well as examples will be explained with reference to the figures.

<FIG> is a schematic configuration diagram of a packaging-container manufacturing apparatus <NUM> for manufacturing packaging containers for smoking articles, according to an embodiment of the present invention. <FIG> is a figure showing schematic shapes of a blank <NUM>, a smoking article <NUM>, and a packaging container <NUM> which are handled in the packaging-container manufacturing apparatus <NUM>. The construction of each of the packaging-container manufacturing apparatus <NUM>, the blank <NUM>, the smoking article <NUM>, and the packaging container <NUM> will be explained with reference to <FIG> and <FIG>.

The packaging-container manufacturing apparatus <NUM> comprises a smoking-article supplying device <NUM>, a blank supplying device <NUM>, an adhesive supplying device <NUM>, an inspection device <NUM>, an assembling device <NUM>, and a conveying device <NUM>. The packaging-container manufacturing apparatus <NUM> is an apparatus for constructing the packaging container <NUM> from the blank <NUM>. The packaging container <NUM> is that into which the smoking article <NUM> is housed and outputted as a finished product from an outlet of the conveying device <NUM>.

The smoking-article supplying device <NUM> supplies the smoking article <NUM> to a part on the conveying device <NUM>. The blank supplying device <NUM> supplies the blank <NUM> to a part on the conveying device <NUM>. The conveying device <NUM> conveys the smoking article <NUM> and the blank <NUM> in the downstream direction. The adhesive supplying device <NUM> and the inspection device <NUM> are positioned on the downstream side of the conveying device <NUM>, and the assembling device <NUM> is positioned on the further downstream side thereof. In the packaging-container manufacturing apparatus <NUM> shown in <FIG>, the smoking-article supplying device <NUM> is arranged on the uppermost stream part of the conveying device <NUM>, however, the above construction is an example, and the position on which the smoking-article supplying device <NUM> is arranged is not specifically limited. For example, the smoking-article supplying device <NUM> may be positioned just upstream the assembling device <NUM>.

The smoking article <NUM> may be a cigarette(s), or electric-heating-type tobacco. Typically, the smoking article <NUM> has an elongated cylindrical shape. For example, plural smoking articles <NUM> are continuously supplied, or a bundle of a number of smoking articles which are to be housed in a single packaging container <NUM>, is supplied to a part on the conveying device <NUM>. A bundle of smoking articles may be wrapped by a packaging material (for example, aluminum foil) for preventing the respective smoking articles in the bundle from coming apart.

The blank <NUM> is a paperboard which has been cut and processed to have a shape that makes it possible to construct therefrom a box-shape packaging container <NUM> which can house the smoking articles <NUM>. For example, the blank <NUM> comprises a front face <NUM>, a back face <NUM>, side faces <NUM> and <NUM>, a top face <NUM>, and a bottom face <NUM>. The blank <NUM> further comprises margins for pasting <NUM>, to each of which an adhesive is applied for constructing the packaging container <NUM> from the blank <NUM>. It should be reminded that a simplified form of the blank <NUM> is drawn in <FIG>, for convenience of explanation. The actual blank <NUM>, from which the packaging container <NUM> is constructed, may have a more complicated shape, the number of faces, or arrangement of the respective faces different from that shown in <FIG>. For example, a blank and a packaging container such as those disclosed in <FIG> of <CIT> may be adopted in the present embodiment.

A brand name, a pattern, an explanation relating to a product, and so on are printed by using various colors on the frontside surfaces (i.e., the faces forming the exterior of the packaging container <NUM>) of the blank <NUM>. On the other hand, the backside surfaces (i.e., the faces inside the packaging container <NUM>) of the blank <NUM> are usually plain white. Further, surfaces of the pasting margins <NUM>, to each of which an adhesive is applied, are also plain white.

The adhesive supplying device <NUM> supplies an adhesive to the pasting margin <NUM> in the blank <NUM> carried on the conveying device <NUM>. For example, the adhesive supplying device <NUM> comprises a nozzle which is constructed to discharge a liquid adhesive. The adhesive supplying device <NUM> further comprises a sensor for detecting the conveying speed of the conveying device <NUM>, or a sensor for detecting the position of each blank <NUM> on the conveying device <NUM>. In synchronous with the moving speed of the conveyed blank <NUM> on the conveying device <NUM>, the adhesive supplying device <NUM> aims at a predetermined position in the pasting margin <NUM> of each blank <NUM> and discharges a droplet of the adhesive thereto. An emulsion, sol, or liquid type adhesive is used as the adhesive. Regarding the color of the adhesive, it is supposed that it has a color that is the same as or similar to the color of the surface, to which the adhesive is applied, of the pasting margin <NUM> in the blank <NUM>. In this regard, the similar colors means two colors that have tones similar to each other and difficult to optically or visually distinguish one from the other.

The inspection device <NUM> inspects whether the adhesive (hereinafter, this may be referred to as a test object) is being supplied to an appropriate position on the blank <NUM>. The construction and operation of the inspection device <NUM> will be explained later.

The assembling device <NUM> forms the packaging container <NUM> by bending the blank <NUM> along predetermined bend lines to transform it to have a three dimensional form, bringing the pasting margins <NUM>, to each of which the adhesive has been applied, to come in contact with predetermined parts of the blank, and making the adhesive be hardened. A predetermined number of smoking articles <NUM> is housed in the constructed packaging container <NUM>. The assembling device <NUM> may put a protection film on the packaging container <NUM>, in which smoking articles <NUM> have been housed, for protecting the packaging container <NUM> from being damaged. In the case that it is judged by the inspection device <NUM> that the adhesive has not been supplied to an appropriate position on the blank <NUM>, assembling device <NUM> may stop operation to construct the packaging container <NUM> from the blank <NUM>, or may exclude the blank <NUM>, with respect to which it is judged that the adhesive has not been supplied to the appropriate position, from the line of the conveying device <NUM>, for avoiding production of a defective product.

<FIG> is a schematic configuration diagram of the inspection device <NUM> according to an embodiment of the present invention. The inspection device <NUM> comprises an illumination unit <NUM>, an imaging unit <NUM>, and an image processing unit <NUM>. The inspection device <NUM> is constructed to detect, by using an image of the blank <NUM> taken by the imaging unit <NUM>, whether the test object is arranged in an appropriate position on the blank <NUM>.

The illumination unit <NUM> is a light source for emitting illumination light to the blank <NUM> on the conveying device <NUM>. The imaging unit <NUM> is an optical sensor for taking an image of the blank <NUM> on the conveying device <NUM> which is illuminated by the illumination light (especially, the pasting margins <NUM> and parts around them), generating electronic image data thereof, and outputting the data. As explained above, the face, to which the adhesive is applied, of the pasting margin <NUM> in the blank <NUM> and the adhesive (i.e., the test object) <NUM> are white, i.e., their colors are the same with each other, or their colors are similar to each other. Thus, in the case that the illumination unit <NUM> and the imaging unit <NUM> are arranged to illuminate or to take an image of the blank from the same direction, both the adhesive and the adhesive-application face are equally illuminated by the illumination light, so that it becomes difficult to discriminate the adhesive, which is the test object and considered to be that existing on the pasting margin <NUM>, in the image data generated by the imaging unit <NUM>.

In the inspection device <NUM> in the present embodiment, the illumination unit <NUM> is arranged to illuminate the blank <NUM> from a first direction D1, and the imaging unit <NUM> is arranged to take an image of the blank <NUM> from a second direction D2 that is different from the first direction D1, as shown in <FIG>. More specifically, the illumination unit <NUM> is arranged to illuminate the blank <NUM> from the first direction D1 that is substantially parallel to the surface of the blank <NUM>, and the imaging unit <NUM> is arranged to take an image of the blank <NUM> from the second direction D2 that is substantially vertical to the surface of the blank <NUM>.

In this manner, since the first direction D1 that the illumination unit <NUM> illuminates the blank <NUM> therefrom and the second direction D2 that the imaging unit <NUM> takes an image of the blank <NUM> therefrom are different from each other, thus, when the adhesive (the test object) <NUM> on the blank <NUM> is viewed from the position of the imaging unit <NUM>, a bright part Sa that appears bright since it is illuminated by the illumination light from the illumination unit <NUM> and a dark part Sb that is shaded since it is not illuminated by the illumination light can be observed on the surface thereof. Further, since the surface of the blank <NUM> is illuminated from the first direction D1 that is substantially parallel thereto, the brightness of the surface of the blank <NUM> becomes that between the brightness of the bright part Sa and the brightness of the dark part Sb. Accordingly, there are differences in brightness in the image data generated by the imaging unit <NUM>; and, based on the differences in brightness, the adhesive (the test object), that has been applied to the white adhesive-application face of the blank <NUM> and is white or has a color similar to white, can be discriminated.

The above-explained arrangement of the illumination unit <NUM> and the imaging unit <NUM> is a mere example of the construction of the inspection device <NUM>. For making it possible to discriminate a test object by using a brightness difference in image data, the illumination unit <NUM> and the imaging unit <NUM> may be arranged to have any positional relation ship that satisfies the condition that a bright part and a dark part can be generated on the surface of the test object <NUM> on the blank <NUM> by illumination light from the illumination unit <NUM>, when the test object <NUM> is observed from the imaging unit <NUM>.

The image processing unit <NUM> is a computer for processing image data generated by the imaging unit <NUM>. The image processing unit <NUM> comprises, at least, a processor <NUM>-<NUM>, a memory <NUM>-<NUM>, and a communication interface <NUM>-<NUM>. The memory <NUM>-<NUM> stores a computer program for executing image processing that will be explained later, other computer programs (for example, an operating system and so on), and various types of setting data. The communication interface <NUM>-<NUM> transmits/receives data to/from an external device. The communication interface <NUM>-<NUM> receives, at least, image data from the imaging unit <NUM>. The received image data is temporarily stored in the memory <NUM>-<NUM>. The processor <NUM>-<NUM> reads, from the memory <NUM>-<NUM>, the image processing program and the image data received from the imaging unit <NUM>, and performs processing according to the image processing program.

<FIG> is a flow chart showing an image processing method <NUM> for inspecting a test object on the blank <NUM>, that is implemented by the image processing unit <NUM> according to an embodiment of the present invention. Although the image processing method <NUM> comprises plural processing steps, the respective processing steps may be performed in the order different from that shown in <FIG> and explained below, if technically or theoretically possible. Further, some processing steps may be omitted if they are not required. The image processing method <NUM> according to the present embodiment will b explained with reference to an example of image data <NUM> shown in <FIG>.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> detects an end edge (an edge) of the blank <NUM> in the image date <NUM>. In the present embodiment, it is supposed that the brightness of the blank <NUM> and the brightness of the background of the blank <NUM> are largely different from each other (for example, the background is sufficiently darker than the blank <NUM>), or they have colors different from each other. The processor <NUM>-<NUM> can detect the edge of the blank <NUM> based on a brightness difference or color difference in the image data. As a result, the position of the blank <NUM> in the image data is identified.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> sets a target arrangement area <NUM> for the test object (the adhesive) in the inside of the blank <NUM> in the image data <NUM>. The target arrangement area <NUM> is an area which is part of the pasting margin <NUM> in the blank <NUM>, and to which the adhesive, which is the test object, is expected to be applied. If the adhesive exists in the target arrangement area <NUM> in the pasting margin <NUM> and does not protrude to the outside of the target arrangement area <NUM>, a quality packaging container <NUM> can be constructed from the blank <NUM>. On the other hand, if the adhesive does not exist in the target arrangement area <NUM> in the pasting margin <NUM>, or if the adhesive protrudes to the outside of the target arrangement area <NUM> although it exists in the target arrangement area <NUM>, a packaging container <NUM> constructed from the blank <NUM> will become a defective product.

The processor <NUM>-<NUM> in the image processing unit <NUM> sets the target arrangement area <NUM> by using, as a reference, the position of the edge of the blank <NUM> in the image data <NUM>. The blank <NUM>, which is a material of the packaging container <NUM>, is made of a paperboard, so that it is likely to be deformed, i.e., bent, curved, or the like, when it is conveyed by the conveying device <NUM>. Thus, even if the imaging unit <NUM> takes an image of the blank <NUM>, which moves at predetermined speed, at appropriate timing, the position of the pasting margin <NUM> in the fringe of the blank <NUM> becomes unstable due to bending, curving, or the like of the paperboard, so that the positions of the pasting margins <NUM> taken as image data may change blank <NUM> by blank <NUM>. The above state is shown in <FIG>. In the image processing method <NUM> according to the present embodiment, the position of the edge of the blank <NUM> in the actually taken image data <NUM> is used as a reference and the target arrangement area <NUM> is set dynamically, so that the target arrangement area <NUM> can be set to be positioned in a correct position, even if the position of the blank <NUM> in the image data <NUM> is unstable.

More specifically, the processor <NUM>-<NUM> in the image processing unit <NUM> sets the target arrangement area <NUM> to be positioned in a position that is a predetermined distance away from the edge of the blank <NUM> in the image data <NUM>. In the example shown in <FIG>, the target arrangement area <NUM> is set to be positioned in a position that is distant from a first edge 210a of the blank <NUM> by distance L1, distant from a second edge 210b of the blank <NUM> by distance L2, and distant from a third edge 210c of the blank <NUM> by distance L3 in the image data <NUM>. The distances L1, L2, and L3 are determined in advance in relation to each product (i.e., the type of the blank <NUM> or the packaging container <NUM>), for example, and stored in the memory <NUM>-<NUM>. The processor <NUM>-<NUM> sets the target arrangement area <NUM> in such a manner that the target arrangement area <NUM> has edges which are positioned in respective positions distant by distances L1, L2, and L3 from the respective edges of the blank <NUM>, that have been detected in the image data <NUM>.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> binalizes the image data. For example, with respect to each pixel in the image data, the processor <NUM>-<NUM> converts a pixel value to a first value (for example, <NUM>) when the pixel value is equal to or greater than a predetermined value, and converts the pixel value to a second value (for example, <NUM>) when the pixel value is less than the predetermined value. The predetermined value that is used as a reference when performing the binarization process may be a value corresponding to brightness higher than the brightness of the dark part Sb of the test object and lower than the brightness of the bright part Sa of the test object and the surface of the blank <NUM>, for example. In the above case, the image data is converted to a binary image wherein the dark part Sb of the test object is represented by a black color, and other parts are represented by a white color. Further, for example, the predetermined value that is used as a reference when performing the binarization process may be a value corresponding to brightness higher than the brightness of the dark part Sb of the test object and the surface of the blank <NUM> and lower than the brightness of the bright part Sa of the test object. In the above case, the image data is converted to a binary image wherein the bright part Sa of the test object is represented by a white color, and other parts are represented by a black color.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> detects the test object in the binary image data. In the above-explained example, the binary image data represents an image wherein the dark part Sb of the test object <NUM> is black and other parts are white, or an image wherein the bright part Sa of the test object <NUM> is white and other parts are black. Thus, the processor <NUM>-<NUM> can identify an image area corresponding to the dark part Sb or the bright part Sa of the test object from the binary image data.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> judges whether the test object has been detected in step <NUM>. The process proceeds to step <NUM> if the test object has been detected, and the process proceeds to step <NUM> if the test object has not been detected.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> identifies relative positions of the test object <NUM> that has been detected in step <NUM> in the image data <NUM>, and the target arrangement area <NUM> that has been set in step <NUM>.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> judges, based on the relative positions of the target arrangement area <NUM> and the detected test object <NUM>, whether the test object <NUM> exists in the target arrangement area <NUM>. If the test object <NUM> exists in the target arrangement area <NUM> and does not protrude to the outside of the target arrangement area <NUM>, the process proceeds to step <NUM>. If the test object <NUM> does not exist in the target arrangement area <NUM>, or if the adhesive protrudes to the outside of the target arrangement area <NUM> although it exists in the target arrangement area <NUM>, the process proceeds to step <NUM>.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> judges that the test object (i.e., the adhesive) <NUM> has been supplied to an appropriate position in the pasting margin <NUM> in the blank <NUM>.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> judges that the test object (i.e., the adhesive) <NUM> has not been supplied to an appropriate position in the pasting margin <NUM> in the blank <NUM>.

In step <NUM>, the processor <NUM>-<NUM> in the image processing unit <NUM> notifies the assembling device <NUM> and the conveying device <NUM> of the state that the test object (i.e., the adhesive) <NUM> has not been supplied to an appropriate position in the pasting margin <NUM> in the blank <NUM>. In response to the notice, the assembling device <NUM> operates to stop the process for constructing the packaging container <NUM>, or exclude the constructed packaging container <NUM>, as explained above. Further, the conveying device <NUM> may stop its conveyance action in response to reception of the notice from the image processing unit <NUM>.

The processor <NUM>-<NUM> in the image processing unit <NUM> performs the image processing method <NUM> with respect to each blank <NUM> conveyed by the conveying device <NUM>.

Claim 1:
An inspection device (<NUM>) for judging a position shift of a test object (<NUM>) to be inspected which is arranged on a blank (<NUM>), from which a packaging container (<NUM>) for a smoking article can be constructed, and has a color similar to a color of the blank (<NUM>), comprising:
an illumination unit (<NUM>) for illuminating, from a first direction, the blank (<NUM>) which includes the test object (<NUM>);
an imaging unit (<NUM>) for taking an image of the blank (<NUM>) including the test object (<NUM>) from a second direction that is different from the first direction, and generating image data (<NUM>); and
an image processing unit (<NUM>) for identifying, based on brightness, a relative position of the test object (<NUM>) with respect to the blank (<NUM>) in the image data (<NUM>),
wherein the image processing unit (<NUM>) is constructed to perform:
a process for identifying a position of the blank (<NUM>) by detecting an edge of the blank (<NUM>) in the image data (<NUM>);
a process for dynamically setting in the image data (<NUM>) a target arrangement area (<NUM>) for the test object (<NUM>) by using the detected edge of the blank (<NUM>) as a position reference;
a process for detecting the test object (<NUM>) based on the brightness in the image data (<NUM>);
a process for identifying relative positions of the detected test object (<NUM>) and the target arrangement area (<NUM>); and
a process for judging, based on the relative positions, whether the test object (<NUM>) is positioned in the target arrangement area (<NUM>) on the blank (<NUM>).