Patent Grant
10682849
This application is based upon and claims the benefit of priority from International Application No. PCT/JP2017/023413, filed on Jun. 26, 2017; Japanese Patent Applications No. 2016-128155, filed on Jun. 28, 2016 and No. 2017-120504, filed on Jun. 20, 2017; the entire contents of all of which are incorporated herein by reference.
Embodiments described herein relate generally to a tablet printing apparatus and a tablet printing method.
A tablet printing apparatus is used to print identification information such as letters or characters (alphabet, kana character, number, etc.) and marks (symbol, figure, etc.) on the surface of a tablet for identifying the tablet. As such tablet printing apparatuses, those that perform printing on tablets in a noncontact manner have been developed due to the ease of changing identification information, high print quality, and the like. An inkjet tablet printing apparatus is configured to eject ink (for example, edible ink) toward tablets while conveying them by a conveyor belt, thereby printing identification information on the surfaces of the tablets. The legibility of the identification information printed on the surface of each tablet is influenced by the density of ink dots formed thereon by the ink ejection from the inkjet head, namely resolution.
The inkjet head of the tablet printing apparatus includes an array of nozzles that are arranged perpendicularly to the tablet conveying direction (hereinafter also simply referred to as “conveying direction”) in the horizontal plane. In tablet printing by the inkjet head, the resolution in the conveying direction according to the tablet conveying speed is determined by the control of timing of the ink ejection from the nozzles of the inkjet head according to the tablet conveying speed. On the other hand, the resolution in a direction perpendicular to the conveying direction is determined by the nozzle pitch in the nozzle array direction. The minimum value of the nozzle pitch of the nozzle array is determined by a limit in processing. Therefore, in order to increase the resolution in the direction perpendicular to the conveying direction, a method of arranging nozzle rows is adopted. Specifically, a plurality of nozzle arrays is used and the nozzles in the nozzle arrays are shifted to be placed in a staggered arrangement (zigzag arrangement) with respect to the conveying direction. For example, nozzles in the second array are each located to face the middle of the nozzle pitch of the nozzle array in the first array.
When printing is performed with the use of a plurality of nozzle arrays as described above, the position and posture (for example, inclination, orientation, etc.) of each tablet may change due to the vibration of the conveyor belt or the like while the tablet moves between the nozzle arrays. In particular, the longer the distance between the nozzle arrays used for printing, the more the position and posture of the tablet are likely to change during printing. A change in the position or posture of the tablet during printing causes a shift in the print position on the tablet where a print is applied by the inkjet head. Accordingly, identification information printed on the tablet is not clear, and the legibility thereof is reduced. As compared to ordinary printing, legibility is important for printing of identification information on tablets. Low legibility can lead to, for example, the misreading of information (such as the type and amount (dose) of medicine) printed on tablets, resulting in misuse of the medicine.
According to one embodiment, a tablet printing apparatus includes a conveying device, an inkjet printing device, and a control device. The conveying device is configured to convey a tablet. The printing device includes a nozzle array in which a plurality of nozzles are arranged in a direction crossing a conveying path where the tablet is conveyed by the conveying device, and performs printing by ejecting ink from the nozzles to the tablet being conveyed by the conveying device. The control device increases either one of a resolution in the conveying direction of the tablet at the time of performing the printing and a resolution in the array direction of the nozzles at the time of performing the printing higher than the other according to a print density or a print shape on the tablet, and controls the printing device to perform the printing.
According to another embodiment, a tablet printing method includes: conveying a tablet by a conveying device; and ejecting ink from a plurality of nozzles of an inkjet printing device to the tablet being conveyed by the conveying device to perform printing. The printing device includes a nozzle array in which the nozzles are arranged in a direction crossing a conveying path where the tablet is conveyed by the conveying device. For the printing, a control device increases either one of a resolution in the conveying direction of the tablet at the time of performing the printing and a resolution in the array direction of the nozzles higher at the time of performing the printing than the other according to a print density or a print shape on the tablet, and controls the printing device to perform the printing.
An embodiment will be described with reference to drawings.
(Basic Configuration)
As illustrated in
The conveying device 20 includes a conveyor belt 21, a driving pulley 22, a plurality of driven pulleys 23 (three in the example of
As illustrated in
Referring back to
The first imaging device 40 is located on the downstream side of the position where the detecting device 30 is located in the conveying direction A1, and is arranged above the conveyor belt 21. The first imaging device 40 performs imaging at the time when the tablet T reaches just under it based on the position information of the tablet T to capture an image (image for printing) including the upper surface of the tablet T, and sends the image to the control device 90. As the first imaging device 40, various cameras having an imaging device such as a charge-coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) can be used. The first imaging device 40 is electrically connected to the control device 90 via the image processing device 80, and is driven under the control of the control device 90. There may also be provided an illumination for imaging as necessary.
The printing device 50 includes an inkjet head 50a (see
The second imaging device 60 is located on the downstream side of the position where the printing device 50 is located in the conveying direction A1, and is arranged above the conveyor belt 21. The second imaging device 60 performs imaging at the time when the tablet T reaches just under it based on the position information of the tablet T to capture an image (image for inspection) including the upper surface of the tablet T, and sends the image to the control device 90. Similarly to the first imaging device 40, various cameras having an imaging device such as CCD or CMOS can be used as the second imaging device 60. The second imaging device 60 is electrically connected to the control device 90, and is driven under the control of the control device 90. There may also be provided an illumination for imaging as necessary.
The collecting device 70 is located on the downstream side of the position where the second imaging device 60 is located in the conveying direction A1. The collecting device 70 is arranged at the end of the conveying device 20 on the downstream side in the conveying direction A1. The collecting device 70 is capable of receiving the tablets T that are released from the hold of the conveying device 20 and sequentially dropped to collect them. The conveying device 20 releases the hold of each tablet T when the tablet T reaches a desired position such as, for example, the end of the conveying device 20 on the downstream side in the conveying direction A1.
The image processing device 80 receives an image for detecting the position of each tablet captured by the first imaging device 40 and an image for inspecting print state (condition) captured by the second imaging device 60, and processes the images by using a known image processing technique.
For example, the image processing device 80 processes the image for detecting the position of each tablet received from the first imaging device 40, and detects the position of the tablet T in the X direction (the conveying direction A1), the Y direction, and the θ direction (see
The image processing device 80 sends the position information of each tablet T in the X direction, the Y direction, and the θ direction and the print position information and the shape information of the print pattern on the each tablet T thus detected to the control device 90. When the each information is sent, the image processing device 80 adds identification information of the imaging device or 60 to the each information and sends it. With this, the control device 90 can figure out whether the received information corresponds to the imaging device 40 or 60.
The control device 90 includes a microcomputer (not illustrated) that intensively controls each unit and a storage (not illustrated) that stores process information, various programs, and the like. The control device 90 controls the supply device 10, the conveying device 20, the first imaging device 40, the printing device 50, the second imaging device 60, and the image processing device 80 based on various information and various programs. The control device 90 also receives detection signals and the like sent from the detecting device 30 and the position detector 25.
For example, based on the position information of the tablet T in the X direction, the Y direction, and the θ direction received from the image processing device 80, the control device 90 sets printing conditions for the tablet T whose positions in the X direction, the Y direction, and the θ direction have been detected. Incidentally, the storage stores print data including a print pattern such as a letter, a character, or a mark, the print position of the print pattern on the tablets T, data on the moving speed of the conveyor belt 21, and the like. The control device 90 determines the use range of the nozzles 51 in the inkjet head 50a of the printing device 50 used for printing of this time based on the position information of the tablet T in the Y direction. The control device 90 also determines the timing at which printing is started on the tablet T based on the position information of the tablet T in the X direction. Further, the control device 90 sets printing conditions correspondingly to the position of the tablet T in the θ direction based on the position information of the tablet T in the θ direction. As an example, 180 types of print data are obtained by rotating a print pattern 1 degree by 1 degree in the range of 0 to 179 degrees, and are stored in the storage of the control device 90 in advance. The control device 90 selects print data with an angle that matches the position in the θ direction from these pieces of print data to set the printing conditions.
Further, the control device 90 determines whether the print pattern (for example, a letter or a character, a mark, etc.) is properly printed on the tablet T based on the print position information and the shape information of the print pattern on the tablet T received from the image processing device 80. Specifically, the control device 90 compares the print pattern printed on the tablet T with a correct print pattern stored therein in advance to make this determination. When the control device 90 determines that the print pattern is properly printed on the tablet T, the tablet T has passed the inspection and is collected by the collecting device 70. On the other hand, if the control device 90 determines that the print pattern is not properly printed on the tablet T, the tablet T has failed the inspection, and is blown by air to be collected by a container other than the collecting device 70.
(Printing Device 50)
Next, the printing device 50 will be described in detail.
As illustrated in
The separation distance (separation distance in the X direction) between the nozzle arrays A and B is set to P. Similarly, the separation distance (separation distance in the X direction) between the nozzle arrays C and D is set to P. Besides, the separation distance (separation distance in the X direction) between the nozzle arrays B and C is set to P×10. In other words, the separation distance between the nozzle arrays B and C is 10 times the separation distance P between the nozzle arrays A and B or between the nozzle arrays C and D. This is because the nozzle arrays B and C must be separated by a large distance due to the structure of the inkjet head 50a (due to the structure for supplying ink to each of the nozzles 51, for ejecting ink from the nozzles 51 individually, etc.).
Assuming that the nozzles 51 are arranged at a nozzle pitch (separation distance) L1 in the nozzle arrays A, B, C, D as illustrated in
The density of ink dots (resolution) formed on the surface of the tablet T by the ink ejection from the inkjet head 50a is defined by the density of ink dots (resolution) in the conveying direction A1 of the tablets T (X direction) and the density of ink dots (resolution) in a direction (Y direction) crossing the conveying direction A1 of the tablets T (X direction). In other words, the density of ink dots (resolution) formed on the surface of the tablet T is determined by the pitch (separation distance) between ink dots in the X direction and the pitch (separation distance) between ink dots in the Y direction. The pitch between ink dots in the X direction (X-direction resolution) depends on the ejection of ink at a timing (time interval) according to the conveying speed of the tablets T to land the ink to the surface of each of the tablets T. The conveying speed of the tablets T is determined in consideration of the printing processing capability, and is set to be constant during printing. The pitch between ink dots in the Y direction (Y-direction resolution) depends on the nozzle pitch in the array direction of the nozzles 51. Therefore, the resolution of printing is determined by the position (nozzle position) where ink is ejected at the time of printing and the timing. The position and timing of ink ejection depend on a dot pattern to eject the ink. That is, the resolution of printing is determined by the resolution of the dot pattern.
In the inkjet head 50a, the nozzle arrays A, B, C, and D are shifted from one another such that the nozzles 51 are arranged in a zigzag manner. With this, the resolution in the array direction of the nozzles 51 (Y direction) can be 600 dpi at the maximum. By using the nozzle arrays A and B or the nozzle arrays C and D in combination, the resolution in the array direction of the nozzles 51 is set to 300 dpi. Besides, by using one of the nozzle arrays A, B, C, and D alone, the resolution in the array direction of the nozzles 51 is set to 150 dpi. In this manner, the resolution in the array direction of the nozzles 51 can be changed by selecting the nozzle array(s) to be used.
In this embodiment, For example, as shown in
The control device 90 selects nozzle arrays to be used for printing from among the nozzle arrays A, B, C, and D based on the first print pattern or the second print pattern. That is, when a print pattern (the first print pattern or the second print pattern) used for printing is set, the control device 90 selects nozzle arrays to be used from all the nozzle arrays A, B, C, and D according to the resolution of the print pattern.
In the case of the print pattern of X: 1200 dpi×Y: 300 dpi, the Y-direction resolution is half of that of the print pattern of X: 600 dpi×Y: 600 dpi, but the X-direction resolution is doubled to compensate it. Accordingly, with the print pattern of X: 1200 dpi×Y: 300 dpi, the number of ink dots in a predetermined area decreases (in this case, halved) in the Y direction and increases (in this case, doubled) in the X direction as compared to the print pattern of X: 600 dpi×Y: 600 dpi, and therefore the number of ink dots in the predetermined area in the both patterns can be considered the same. In other words, the density of ink dots landed to the tablet T is halved in the Y direction and is doubled in the X direction. Thereafter, as illustrated on the right side in
As described above, each of the nozzles 51 is set to constantly eject the same amount of ink, and all the nozzles 51 eject the same or nearly the same amount of ink. Therefore, the total amount of ink ejected to one tablet T is determined by the number of times of ink ejection. There is no difference in the total amount of ink ejected to one tablet T between the first print pattern and the second print pattern of this embodiment.
(Generation of Print Pattern)
Next, a procedure of generating a print pattern will be described. As illustrated in
First, the operator enters identification information such as a letter, a character, or a mark by operating the input unit 93, and the control device 90 stores the identification information as an image. The operator also enters a resolution by using the input unit 93, and the resolution setting unit 91 sets the resolution according to the input. For example, when the resolution setting unit 91 sets the resolution to X: 600 dpi×Y: 600 dpi, the pattern generating unit 92 overlays the entered image (input image) G1 on a matrix M1 corresponding to the resolution “X: 600 dpi×Y: 600 dpi” as illustrated in
When the resolution is changed, for example, when the resolution is changed from X: 600 dpi×Y: 600 dpi to X: 1200 dpi×Y: 300 dpi, the pattern generating unit 92 generates a print pattern of X: 1200 dpi×Y: 300 dpi in the same manner as described above. That is, the pattern generating unit 92 generates a print pattern to be used according to the resolution entered.
If the dot pattern generated by the matrix of X: 600 dpi×Y: 600 dpi is reused as a dot pattern of X: 1200 dpi×Y: 300 dpi, for example, the print is deformed and not clear. When a dot pattern of X: 600 dpi×Y: 600 dpi is generated from an image, the part where ink dots are applied in the matrix is determined to achieve clear print results. Specifically, for example, when a line of the image runs across a plurality of cells of the matrix, the cells where ink dots are applied are selected to achieve clear print results. In the case of reusing the dot pattern obtained in this manner, the dots are added or reduced, resulting in the deformation of the print shape. Therefore, in order to change the resolution, a dot pattern is newly generated according to a matrix of the resolution. With this, the dot pattern suitable for printing is obtained. Further, reliable and fast processing can be achieved as compared to the case of reusing the same dot pattern.
In the resolution setting described above, the first print pattern or the second print pattern, or the arbitrary combination of the X-direction resolution and the Y-direction resolution, or the like can be set appropriately based on past printing results and the like. Further, for example, an image for print check (print check image) may be displayed on the display 94. In this case, the operator can check the print density or the print shape while viewing the print check image to enter the resolution by using the input unit 93. The resolution setting unit 91 sets the resolution according to the input of the resolution. The operator can also adjust the density (for example, a value of gray scale or a percentage of density) by using the input unit 93 while viewing the print check image. The resolution setting unit 91 sets the resolution according to the adjustment of the density. As a result, the resolution setting unit 91 sets the resolution according to the print density or the print shape on the tablets T. The print density refers to the density (color intensity) of a letter, a character, a mark, or the like printed on the tablets T. The print shape refers to the shape of a letter, a character, a mark, or the like printed on the tablets T. A new print pattern is generated according to the resolution changed, and the operator checks the appearance (density and shape) of the print again while viewing a print check image corresponding to the new print pattern. The appearance of the print need not necessarily be checked with the print check image displayed on the display 94, and may be checked at another place (off-machine, offline).
In addition, correlation between the print resolution and the print density may be obtained in advance, and setting for the adjustment of the resolution and the print density can be performed based on the correlation. For example, in the ink prepared as a reference and the tablets T, or the ink to be used and the tablets T to be printed, using a reference print shape or a print shape (a letter or a character, a mark, etc.) to be used for printing, correlation data may be generated to be stored in advance by changing the resolution in the conveying direction A1 of the tablets T at regular intervals and measuring the print density with an inspection device (for example, the second imaging device 60) of the apparatus. As the correlation data, a correlation table indicating the correlation between the X-direction resolution (resolution in the conveying direction A1 of the tablets T) and the print density can be used. With this, correlation can be derived from correlation data in various inks and the tablets T as well as print shapes. By using the correlation, an input reference value can be presented on the display 94 at the time of inputting the density. Further, the selected value of the resolution with respect to the input value of the density or the prediction of changes in density as to the input value of the density can also be presented on the display 94. Incidentally, the check of the print density includes the check of the spread degree of ink.
(Specific Printing Operations)
Next, specific printing operations of the printing device 50 will be described. For example, a description will be given of the case where a first straight line extending in the Y direction is printed on the tablet T that is moving as conveyed by the conveyor belt 21 with reference to
In the upper diagram of
(First Printing Operation)
First, when the tablet T arrives just under the nozzle array A, ink is ejected from the nozzles 51 in the numbers 1 and 5 in the nozzle array A. Thereby, two ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots. The ink stops spreading when it has spread to some extent (the same applies to other ink dots). Then, when the tablet T has moved by the separation distance P (see
Thereafter, when the tablet T has moved by the separation distance P×10 from under the nozzle array B, and arrives just under the nozzle array C, ink is ejected from the nozzles 51 in the numbers 2 and 6 in the nozzle array C. As a result, in addition to the four ink dots formed by the nozzle arrays A and B, two ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots. Further, when the tablet T has moved by the separation distance P from under the nozzle array C, and arrives just under the nozzle array D, ink is ejected from the nozzle 51 in the number 4 in the nozzle array D. As a result, in addition to the six ink dots formed by the nozzle arrays A, B and C, one ink dot is formed on the surface of the tablet T, and the ink spreads from the ink dot.
In the example of
(Second Printing Operation)
First, when the tablet T arrives just under the nozzle array A, ink is ejected from the nozzles 51 in the numbers 1 and 5 in the nozzle array A. Thereby, two ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots. Then, when the tablet T has moved by the separation distance P from under the nozzle array A, and arrives just under the nozzle array B, ink is ejected from the nozzles 51 in the numbers 3 and 7 in the nozzle array B. As a result, in addition to the two ink dots formed by the nozzle array A, two ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots.
In the example of
(Third Printing Operation)
First, when the tablet T arrives just under the nozzle array A, ink is ejected from the nozzles 51 in the numbers 1 and 5 in the nozzle array A. Then, ink is ejected again from the nozzles 51 in the numbers 1 and 5 at a predetermined timing. Thus, ink ejection is performed twice in total from the nozzle array A. Thereby, four ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots. After that, when the tablet T has moved by the separation distance P from under the nozzle array A, and arrives just under the nozzle array B, ink is ejected from the nozzles 51 in the numbers 3 and 7 in the nozzle array B. Then, ink is ejected again from the nozzles 51 in the numbers 3 and 7 at a predetermined timing. Thus, ink ejection is performed twice in total from the nozzle array B. As a result, in addition to the four ink dots formed by the nozzle array A, four ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots.
Thereafter, when the tablet T has moved by the separation distance P×10 from under the nozzle array B, and arrives just under the nozzle array C, ink is ejected from the nozzles 51 in the numbers 2 and 6 in the nozzle array C. Then, ink is ejected again from the nozzles 51 in the numbers 2 and 6 at a predetermined timing. Thus, ink ejection is performed twice in total from the nozzle array C. As a result, in addition to the eight ink dots formed by the nozzle arrays A and B, four ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots. Further, when the tablet T has moved by the separation distance P from under the nozzle array C, and arrives just under the nozzle array D, ink is ejected from the nozzle 51 in the number 4 in the nozzle array D. Then, ink is ejected again from the nozzle 51 in the number 4 at a predetermined timing. Thus, ink ejection is performed twice in total from the nozzle array D. As a result, in addition to the twelve ink dots formed by the nozzle arrays A, B, and C, two ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots.
In the example of
(Fourth Printing Operation)
First, when the tablet T arrives just under the nozzle array A, ink is ejected from the nozzles 51 in the numbers 1 and 5 in the nozzle array A (first time). Then, ink is further ejected from the nozzles 51 in the numbers 1 and 5 at predetermined intervals (at a predetermined timing) three times. Thus, ink ejection is performed four times in total from the nozzle array A. Thereby, eight ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots. After that, when the tablet T has moved by the separation distance P from under the nozzle array A, and arrives just under the nozzle array B, ink is ejected from the nozzles 51 in the numbers 3 and 7 in the nozzle array B (first time). Then, ink is further ejected from the nozzles 51 in the numbers 3 and 7 at predetermined intervals (at a predetermined timing) three times. Thus, ink ejection is performed four times in total from the nozzle array B. As a result, in addition to the eight ink dots formed by the nozzle array A, eight ink dots are formed on the surface of the tablet T, and the ink spreads from these ink dots.
In the example of
In the example of
The timing for the ink ejection in the X direction (conveying direction A1) is determined under the condition that the conveying speed is constant. Accordingly, even when a print pattern is replaced with another one, the conveying speed is unchanged and maintained constant. Besides, when the timing is considered in terms of not time but conveyance distance, in 600 dpi printing, ink is ejected again when the tablet T has moved by 25.4 mm/600 d=0.0423 mm (42.3 μm). In 1200 dpi printing, ink is ejected again when the tablet T has moved by 25.4 mm/1200 d=0.0212 mm (21.2 μm) (4 times in total).
As described above, high-resolution printing can be performed by the use of combinations of a plurality of nozzle arrays A, B, C, and D, in which nozzles are arranged in a staggered manner, for ink ejection. Incidentally, for example, if the tablets T to be printed have a curved surface and the surface is sucked during conveyance, the area sucked and held is smaller as compared to when the surface is flat. Such tablets T are likely to be shaky on the conveyor belt 21 and easily roll over. Accordingly, the position and posture of each of the tablets T are highly likely to change due to the vibration of the conveyor belt 21 or the like. A change in the position and posture of the tablet T causes the displacement of the print position, where a print is applied by the printing device 50, on the tablet T. In particular, when the position and posture change when the tablet T moves between the nozzle arrays, the positions of ink dots landed from the nozzle arrays are mutually misaligned. This results in unclear print of identification information on the tablet T.
As described above, in this embodiment, the separation distance between the nozzle arrays B and C is P×10, which is longer than the separation distance P between the nozzle arrays A and B or between the nozzle arrays C and D. Therefore, the position and posture of the tablet T are more likely to change while the tablet T is moving between the nozzle arrays B and C than while it is moving between the nozzle arrays A and B or between the nozzle arrays C and D.
Meanwhile, the separation distance between the nozzle arrays A and B is P, which is much shorter than the separation distance P×10 between the nozzle arrays B and C. Therefore, when printing is performed with only the two nozzle arrays A and B, the position and posture of the tablets T conveyed by the conveyor belt 21 are less likely to change due to the vibration of the conveyor belt 21 or the like. Even if the conveyor belt 21 vibrates, the shift amount of the tablet T is small since the movement distance of the tablet T between the nozzle arrays is short. Accordingly, the print position is less displaced on the tablet T due to a change in the position and posture of the tablet T. Therefore, in the case of printing with only the nozzle arrays A and B, a decrease in the legibility of identification information printed on the tablet T can be suppressed. Besides, when printing is performed with the two nozzle arrays A and B, the Y-direction resolution (resolution in the array direction of the nozzles 51) is reduced to half of that of printing with the nozzle arrays A, B, C, and D. However, as the X-direction resolution (resolution in the conveying direction A1 of the tablets T) is doubled to compensate it, it is possible to further suppress a decrease in the legibility of identification information printed on the surface of the tablet T.
Incidentally, on the upper side of the conveying device 20, the suction force of the suction chamber 26 is reduced compared to other areas. This is to suppress airflow generation caused by the suction of air from the suction holes 21a of the conveyor belt 21. If a high-speed large airflow is generated, ink ejected from the nozzles 51 of the inkjet head 50a are bent or blown off by the airflow, resulting in a reduction in print quality. In order to prevent this, the suction force is reduced on the upper side of the conveying device 20, particularly in the area facing the inkjet head 50a, as described above. For this reason, the tablets T are liable to shift. On the other hand, on the surface of the conveyor belt 21 around the outer periphery of the driving pulley 22, the suction force of the suction chamber 26 is increased compared to other areas. This is to prevent the tablets T from falling from the surface of the conveyor belt 21 around the outer periphery of the driving pulley 22 due to the centrifugal force.
(Printing Process)
In the following, a description will be given of printing process and inspection process performed by the tablet printing apparatus 1.
First, various information such as print data required for printing is stored in the storage of the control device 90. Then, when a number of tablets T to be printed are put in the hopper 11 of the supply device 10, the tablets T are sequentially supplied from the hopper 11 to the chute 12, and supplied to the conveyor belt 21 as being aligned in a row by the chute 12. The conveyor belt 21 is rotating in the conveying direction A1 with the rotation of the driving pulley 22 and the driven pulleys 23 caused by the motor 24. Accordingly, the tablets T supplied onto the conveyor belt 21 are conveyed at a predetermined moving speed in a row on the conveyor belt 21.
Thereafter, the detecting device 30 detects each of the tablets T on the conveyor belt 21. Thereby, position information (the position in the conveying direction A1) of the tablet T is acquired and fed to the control device 90. The position information of the tablet T is stored in the storage of the control device 90 and used for post-processing. Next, the first imaging device 40 captures an image of the tablet T on the conveyor belt 21 at the timing based on the position information of the tablet T, and sends the image to the image processing device 80. The image processing device 80 generates position shift information of the tablet T (for example, as to the position shift of the tablet T in the X direction, the Y direction, and the θ direction) based on each image received from the first imaging device 40. The position shift information is stored in the storage of the control device 90. The control device 90 sets printing conditions (ejection position and ejection speed of ink, etc.) for the tablet T based on the position shift information of the tablet T. The printing conditions are stored in the storage of the control device 90.
Subsequently, the printing device 50 performs printing on each of the tablets T on the conveyor belt 21 according to the printing conditions at the timing based on the position information of the tablet T, i.e., at the timing when the tablet T reaches under the printing device 50. In the printing device 50, ink is appropriately ejected from each of the nozzles 51. Thus, identification information such as a letter or a character (for example, alphabet, kana character, number), a mark (for example, symbol, figure), or the like is printed on the upper surface of the tablet T.
The second imaging device 60 captures an image of the tablet T having the identification information printed thereon at the timing based on the position information of the tablet T, and sends the image to the image processing device 80. The image processing device 80 generates shape information and print position information indicating the print position of a print pattern for each of the tablets T based on each image received from the second imaging device 60. The shape information and the print position information are stored in the storage of the control device 90. The control device 90 determines print quality as to whether the print on the tablet T is acceptable based on the shape information and the print position information, and stores print quality determination result information indicating the result of the print quality determination for each of the tablets T in the storage thereof. For example, the control device 90 checks whether the print pattern is printed at a predetermined position on the tablet T to determine the print quality.
The tablet T after the inspection is conveyed with the movement of the conveyor belt 21, and arrives at the end of the conveying device 20 on the downstream side in the conveying direction A1. At this position, the tablet T is released from the hold of the conveyor belt 21. As a result, the tablet T is dropped from the conveyor belt 21 and collected by the collecting device 70. For example, if the print quality is acceptable, the tablet T is just dropped and collected by the collecting device 70 as a non-defective product passed with printing. On the other hand, if the print quality is not acceptable, the tablet T is blown by air while dropping and collected by a container other than the collecting device 70 as a defective product that failed printing.
(Print States with Respect to Print Patterns of Various Resolutions)
In the print process, the inkjet printing device 50 performs printing on the tablets T based on a print pattern. Referring to
In the case of printing with a print pattern of X: 600 dpi×Y: 600 dpi, all the four nozzle arrays A, B, C, and D are used, and usually “A” is clearly printed on the tablet T as illustrated in
(Verification by Printing Test)
To verify the above, a printing test was performed on the tablets T on which ghost printing tended to occur using only the two nozzle arrays A and B or the two nozzle arrays C and D. As a result, “A” was printed as illustrated in
(Study for Sharpening at Low Resolution)
Therefore, the present inventors tried using a larger amount of ink to increase the resolution in the conveying direction A1 to thereby increase the print density. The results confirmed that, as illustrated in
In view of the foregoing, when the position and posture of the tablets T change while they are moving between the nozzle arrays, a couple of nozzle arrays with a shorter separation distance are used and the print state is adjusted by the X-direction resolution (resolution in the conveying direction A1). Specifically, the X-direction resolution (resolution in the conveying direction A1) is increased to compensate the reduction in the Y-direction resolution (resolution in the array direction of the nozzles) due to the use of less number of nozzle arrays. This is easier than increasing the amount of ink ejected from each of the nozzles 51. Thereby, a clear print can be made stably even on the tablets T having a shape that makes their positions and postures prone to change on the conveyor belt 21. Besides, even if the print state is as illustrated in
the image processing device 80 generates position shift information for each of the tablets T (information as to the reference position of the tablet T in the XY-coordinate system, i.e., the position shift of the tablet T in the X direction, the Y direction, and the θ direction from the origin) based on each image received from the first imaging device 40. When the tablet T has shifted in the Y direction, the control device 90 shifts (offsets) a print pattern to be used based on the pitch that corresponds to the resolution of the print pattern in the array direction of the nozzles 51 according to the shift amount of the tablet T in the Y direction, and determines the nozzles 51 to be used in each of the nozzle arrays. For example, when printing is performed on the tablets T with the second print pattern, the control device 90 shifts the print pattern by L1/2 since the pitch thereof is L1/2 in the array direction of the nozzles 51, and determines the nozzles 51 to be used in each of the nozzle arrays accordingly.
Specifically, assuming, for example, that the tablet T has shifted by about L3/4 in the +Y direction when printing is performed using the nozzles 51 in the reference numbers 1, 3, and 5 in the nozzle arrays A and B illustrated in
As described above, according to the first embodiment, the inkjet printing device 50 having at least one array of nozzles performs printing at an X-direction resolution (resolution in the conveying direction A1 of the tablets T), which is increased higher than the Y-direction resolution (resolution in the array direction of the nozzles) according to the print density or the print shape on the tablets T. The printing device 50 generates a dot pattern for printing according to the set resolution. In other words, the control device 90 increases either one of the X-direction resolution and the Y-direction resolution for printing higher than the other according to the print density or the print shape on the tablets T, and controls the printing device 50 to perform printing at the resolutions. Thereby, even when the posture and position of the tablets T are prone to change on the conveyor belt 21, a decrease in the legibility of identification information printed on the tablets T can be suppressed. Thus, the misuse of the tablets T can be prevented.
In the above embodiment, an example is described in which printing is performed with a print pattern of X: 1200 dpi×Y: 300 dpi using the two nozzle arrays A and B; however, it is not so limited. For example, printing can also be performed with a print pattern of X: 2400 dpi×Y: 150 dpi using the one nozzle array A. In this case, although the Y-direction resolution is reduced, the X-direction resolution is increased to compensate it. Therefore, it is possible to ensure the total amount of ink ejection necessary for clear print results. Further, as an optimum print pattern (dot pattern) is generated for X: 2400 dpi×Y: 150 dpi printing, a decrease in the legibility of identification information printed on the tablets T can be suppressed.
In the above embodiment, an example is described in which printing is performed with a print pattern of X: 1200 dpi×Y: 300 dpi using the two nozzle arrays A and B; however, it is not so limited. Arbitrary combinations of nozzle arrays such as, for example, the nozzle arrays A and C, A and D, and A, C, and D can also be used. Depending on the shape of the tablets T and the distance between the nozzle arrays, the tablets T are less shaky while moving between the nozzle arrays or there is no influence on printing. In such a case, there may be no need to minimize the distance between the nozzle arrays to be used. Depending on the print shape (the shape of a letter or a character, a mark, etc. to be printed or the condition of the shape of the print), the nozzle array(s) that can achieve the best print results may be selected.
In the above embodiment, an example is described in which a new print pattern (dot pattern) is generated each time the resolution is changed; however, it is not so limited. For example, the control device 90 may store print patterns (dot patterns) of possible resolutions in advance and select a specific one of them for use. However, when the resolution is changed to adjust the density, the resolution used may be extremely fine (for example, 657 dpi, 1188 dpi, etc.). In order to select a print pattern, the control device 90 includes a resolution selecting unit (selector: not illustrated) that selects a print pattern (resolution) to be used from a plurality of print patterns of the same identification information with different resolutions according to an input provided by the operator on the input unit 93. The resolution selecting unit may be realized only by hardware such as a circuit, or may be realized by both hardware and software.
In the above embodiment, for example, the total number of ejection times of the first print pattern and the total number of ejection times of the second print pattern are the same; however, this does not necessarily mean that exactly the same amount of ink is ejected in total. It suffices if printing is performed with about the same amount of ink, and the legibility of prints is at about the same level. For example, when printing is performed with a print pattern of X: 1200 dpi×Y: 300 dpi according to the pattern shape of identification information to be printed, the surface condition of the tablets T, the viscosity and drying properties of ink, and the like, the print density may be too high or too low as compared to printing with a print pattern of X: 600 dpi×Y: 600 dpi (even if the same amount of ink is ejected in total), and also the print shape may be deformed. This can be solved by setting the X-direction resolution appropriately. For example, if the Y-direction resolution is 300 dpi, the X-direction resolution is set to a value between 700 dpi and 1400 dpi to adjust the total amount of ejected ink, thereby achieving an appropriate print density or print shape.
Specifically, in the observation of the print state, if the density of print (print density) is low, the X-direction resolution is increased so that a larger more amount of ink is ejected in the X direction. In the above example, the resolution is changed from X: 1200 dpi×Y: 300 dpi to X: 1280 dpi×Y: 300 dpi or the like. On the other hand, when the print density is high, the X-direction resolution is reduced so that less amount of ink is ejected in the X direction. In the above example, the resolution is changed from X: 1200 dpi×Y: 300 dpi to X: 990 dpi×Y: 300 dpi or the like. Besides, when the print shape is not clear due to significant ink feathering or spreading caused by the use of a large amount of ink, the X-direction resolution is reduced so that less amount of ink is ejected in the X direction. In the above example, the resolution is changed to X: 990 dpi×Y: 300 dpi or the like. When the spacing of ink dots is too wide and the print shape is so unclear that it is difficult to read it, in the above example, the resolution is changed to X: 1280 dpi×Y: 300 dpi or the like. By increasing the X-direction resolution, the amount of ink applied is increased so that ink dots are combined. The Y-direction resolution may be similarly changed depending on the print state.
As described above, the Y-direction resolution (resolution in the array direction of the nozzles) is determined by the pitch of the nozzles 51. Therefore, available resolutions are limited as in this embodiment where the use of the four nozzle arrays provides some options of resolution such as 150 dpi, 300 dpi, and 600 dpi. On the other hand, the X-direction resolution (resolution in the conveying direction A1 of the tablets T) is determined by the timing of ink ejection. Thus, the X-direction resolution can be set with a high degree of freedom, thereby achieving finer adjustment of the print density.
Even when printing is performed with a print pattern of X: 600 dpi×Y: 600 dpi, there are cases where the print density may seem too high. This can also be solved by setting the X-direction resolution appropriately. For example, when ink dots are printed using too much ink, the ink takes time to dry. As a result, the ink may adhere to the conveyor belt 21 and other tablets T, thus smearing, or the print may be unclear due to significant ink feathering or spreading. This occurs depending on the surface condition of the tablets T and the properties of the ink. Therefore, the X-direction resolution is set to a value lower than 600 dpi to adjust the total amount of ejected ink, thereby achieving an appropriate print density or print shape. With this, it is possible to reduce defects in prints due to excessive ink amount.
In the above embodiment, the total amount of ink ejected to one tablet T is described as being determined by the number of times of ink ejection in printing with the second print pattern; however, this is by way of example, and it can be adjusted by increasing the amount of ink ejected from the nozzles 51 at one time. The total amount of ejected ink can be determined by both the amount of ink ejected from the nozzles 51 and the number of times of ink ejection. Note that the maximum amount of ink that can be ejected from the one nozzle 51 is already determined. Therefore, assuming that the total amount of ink ejected to one tablet from the nozzles 51 in printing with the first print pattern is the maximum amount per tablet, when printing on each of the tablets T with the second print pattern requires the same or more amount of ink than that with the first print pattern, the total amount of ejected ink has to be adjusted by the number of times of ink ejection.
The total amount of ejected ink can be increased by ejecting ink a plurality of times to the same dot positions in a print pattern (dot pattern). When printing is performed by relative movement, the positions of ink dots are displaced in the relative movement direction. Accordingly, the ink dots at the displaced positions appear as if spreading in the relative movement direction. However, even when the dot of ink spreading in the movement direction by this way lands to one dot in a dot pattern, the resolution of printing is determined by checking the print density and the print shape under this condition, and an optimum dot pattern is generated according to the resolution. Thus, it is possible to suppress a decrease in the legibility of identification information printed on the tablets T.
In the above embodiment, a print head having a plurality of nozzle arrays is described as the inkjet printing device 50; however, this is by way of example and not limitation. For example, the inkjet printing device 50 may be a print head having a single nozzle array. In this case, although the Y-direction resolution decreases, the X-direction resolution can be increased to achieve the total amount of ink ejection necessary for clear print results. With this, a decrease in the legibility of identification information printed on the tablets T can be suppressed. Further, the inkjet printing device 50 may be a plurality of print heads having an array of nozzles arranged in the conveying direction A1 of the tablets T. In this case, the instability of print results is likely to occur but it can be overcome as in the above cases. Thus, it is possible to suppress a decrease in the legibility of identification information printed on the tablets T as in the above embodiment.
In the above embodiment, the print head is described as having four nozzle arrays is described; however, this is by way of example and not limitation. The print head can be provided with any number of nozzle arrays such as, for example, two arrays, three arrays, six arrays, or the like.
In the above embodiment, the separation distance (separation distance in the X direction) between the nozzle arrays B and C is described as being ten times longer than the separation distance P between the nozzle arrays A and B or between the nozzle arrays C and D; however, this is by way of example and not limitation. The separation distance between the nozzle arrays B and C may be the same as (1 time), or 20 times, 30 times longer than the separation distance P. That is, the separation distance between the nozzle arrays B and C includes a distance where the position and posture of the tablets T may change during conveyance.
In the above embodiment, printing with the second print pattern is performed using the nozzle arrays A and B; however, it is not so limited, and it may be performed using the nozzle arrays C and D. Further, the combination of the nozzle arrays A and B and the combination of the nozzle arrays C and D may be switched or alternately used. If printing is performed using the combinations of nozzle arrays alternately in this manner, the life of the nozzles 51 can be extended, and printing can be performed stably. In addition, as the inkjet head 50a requires less frequent maintenance, productivity in tablet printing can be improved. When printing is performed with one nozzle array, it may be switched to or used alternately with another nozzle array.
Further, for example, printing with a print pattern of X: 4800 dpi×Y: 75 dpi can be performed using every other nozzles 51 in the nozzle array A. In this case, the nozzles 51 in use can be switched to or used alternately with those not in use. With this, the life of the nozzles 51 can be extended, and printing can be performed stably. In addition, as the inkjet head 50a requires less frequent maintenance, productivity in tablet printing can be improved. In this case also, an optimum dot pattern is generated according to the resolution, and clear print results can be achieved.
Incidentally, when printing is performed using every other nozzles of one nozzle array, the resolution is reduced to half. In the case of a plurality of nozzle arrays, printing can be performed using a combination of half of nozzles of the nozzle arrays at a combined resolution. A combination of the nozzles that can achieve the best print results may be determined according to the shape of a letter, a character, a mark, or the like used for printing. In this case, the control device 90 determines nozzle arrays and nozzles in the nozzle arrays used for printing based on a print pattern (dot pattern).
As described above, by adjusting the resolution of printing, i.e., the X-direction resolution and the Y-direction resolution, according to the print density, clear printing can be obtained stably. Thus, it is possible to suppress a decrease in the legibility of identification information printed on the tablets T.
As described above, the setting and the combination of the Y-direction resolution and the X-direction resolution, nozzles or nozzle array(s) to be used and the combination thereof can be determined arbitrarily. In any case, the print density is checked to adjust the Y-direction resolution and the X-direction resolution, and an optimum dot pattern is generated according to the resolutions to perform printing. With this, printing is performed with little decrease in the legibility regardless of the shape of the tablets, the shape of the print pattern, and the structure of the nozzles or the nozzle array(s) of the print head.
In the above embodiment, the tablets T are described as being conveyed in a row; however, this is by way of example, and the number of rows of tablets is not particularly limited. There may be two rows, three rows, or four or more rows.
In the above embodiment, there is provided only one conveyor belt 21; however, this is by way of example, and the number of conveyor belts is not particularly limited. There may be provided two or more conveyor belts. For example, a plurality of conveyor belts 21 may be arranged in parallel.
In the above embodiment, the suction holes 21a of the conveyor belt 21 are described as being circular; however, this is by way of example, and the shape of the suction holes 21a is not particularly limited. The suction holes may be in a rectangular shape, an elliptical shape, or a slit-like shape.
In the above embodiment, the suction force of the suction chamber 26 is reduced on the upper side of the conveying device 20 as compared to other areas; however, this is by way of example and not limitation. If there is little influence of airflow, which may cause ink ejected from the nozzles 51 of the inkjet head 50a to bent or blow off and thereby reduce the print quality, the suction force does not need to be reduced.
In the above embodiment, one inkjet printing device 50 is provided for the conveying path of the tablets T; however, this is by way of example and not limitation. For example, when there are a plurality of conveying paths, the inkjet printing device 50 may be provided for each of the conveying paths.
In the above embodiment, the timing of printing is determined based on position information acquired by the detecting device 30; however, this is by way of example and not limitation. For example, the timing of printing may be determined based on an image captured by the first imaging device 40.
In the above embodiment, the ink applied to the tablets T is left to dry naturally; however, this is by way of example and not limitation. For example, a dryer can be used to dry the ink applied to the tablets T.
In the above embodiment, one conveying device 20 is provided to perform printing on one side of the tablet T; however, this is by way of example and not limitation. For example, two conveying devices 20, each provided with various equipment such as the printing device 50, may be arranged one on top of the other to perform printing on either one or both sides of the tablet T.
The above-described tablets may include tablets for pharmaceutical use, edible use, cleaning, industrial use, and aromatic use. Examples of the tablets include plain tablets (uncoated tablets), sugar-coated tablets, film-coated tablets, enteric coated tablets, gelatin coated tablets, multilayered tablets, dry-coated tablets, and the like. Examples of the tablets further include various capsule tablets such as hard capsules and soft capsules. The tablets may be in a variety of shapes such as, for example, a disk shape, a lens shape, a triangle shape, an elliptical shape, and the like. In the case where tablets to be printed are for pharmaceutical use or edible use, edible ink is suitably used. As the edible ink, any of synthetic dye ink, natural color ink, dye ink, and pigment ink may be used.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; further, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-128155 | Jun 2016 | JP | national |
| 2017-120504 | Jun 2017 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 6328404 | Fujimori | Dec 2001 | B1 |
| 20090015617 | Odaka et al. | Jan 2009 | A1 |
| 20110128557 | Kinoshita | Jun 2011 | A1 |
| 20160021907 | Cavin et al. | Jan 2016 | A1 |
| 20170259595 | Aoyagi et al. | Sep 2017 | A1 |
| Number | Date | Country |
|---|---|---|
| 7-81050 | Mar 1995 | JP |
| 2000-225716 | Aug 2000 | JP |
| 2009-18534 | Jan 2009 | JP |
| 10-2006-0040031 | May 2006 | KR |
| WO2016084812 | Jun 2016 | WO |
| Entry |
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| International Search Report dated Jul. 25, 2017 in PCT/JP2017/023413, filed on Jun. 26, 2017. |
| Number | Date | Country | |
|---|---|---|---|
| 20190099996 A1 | Apr 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2017/023413 | Jun 2017 | US |
| Child | 16206338 | US |
