Apparatus, system and method for vial seal inspection

Abstract

The apparatus, system, or method for vial seal inspection may be based on three-dimensional data representative of at least a portion of a vial seal. More particularly, the apparatus, system, and method for vial seal inspection may include at least one laser triangulation sensor.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS Priority is claimed to U.S. Provisional Patent Application No. 63 / 235,834, filed August 23, 2021, the entire contents of which are incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to apparatus, systems, and methods for vial seal inspection using three-dimensional data representative of at least a portion of a vial seal, and more particularly, to apparatus, systems, and methods for vial seal inspection using a laser triangulation sensor. [Background technology]

[0003] Under FDA regulations, many products (e.g., filled and sealed vials of pharmaceutical products) must be 100% inspected. Vial seal crimp inspection is one example. Vial seal crimp inspection is currently performed using two-dimensional (2D) vision-based inspection. Among other sources of error, known 2D vial seal crimp inspection is prone to errors due to the lighting conditions involved.

[0004] Variations in the crimp material (e.g., anodized forms of aluminum, etc.) can result in different reflectance levels. Thus, if an associated 2D vision system is configured to detect defects in one batch of aluminum vial seals, for example, the system may be successful with a batch of sealed vials. However, future batches of sealed vials may not have the same image due to variations in the finish of the seal surface, slight variations in the color of the vial seal surface, etc. Known 2D vial seal crimp inspections often involve illuminating the associated vial seal crimp area of ​​each vial during inspection. All of these issues can cause false rejects (i.e., a false reject is a sealed vial with a good vial seal crimp that is erroneously deemed a bad vial seal). In any event, known inspection system errors often result in false rejects.

[0005] Vial seal crimping processes often involve mechanical steps that may be performed after the associated vial has been successfully filled. As described in detail herein, vial seal crimping defects often occur due to variations in the mechanical nature of the vial seal crimping process and / or the associated vials (e.g., glass containers, etc.).

[0006] As part of the filled and sealed vial inspection, known 2D vial seal crimp inspection may be incorporated into an automated visual inspection (AVI) system. In known vial seal inspection systems, a sealed vial may be rotated 360 degrees about the central axis of the vial, and multiple two-dimensional (2D) images may be taken at various points relative to the vial rotation, and these 2D images may be analyzed using machine vision-based algorithms to detect, for example, seal defects. False rejects often occur due to variability in the associated 2D vision-based system.

[0007] What is needed is an apparatus, system, and method for vial seal inspection to reduce false rejects compared to traditional 2D vision based vial seal inspection. What is needed is an apparatus, system, and method for vial seal inspection using 3D data representative of at least a portion of the vial seal surface. What is also needed is an apparatus, system, and method for vial seal inspection using at least one laser triangulation device. Summary of the Invention [Means for solving the problem]

[0008] The vial seal inspection system may include a vial seal distance data generating device configured to generate vial seal distance data. The vial seal distance data may represent a plurality of distance measurements correlated with points along at least a portion of a line extending from a top of the vial seal to a bottom edge of the vial seal. The system may also include a vial seal perimeter data generating device configured to generate vial seal perimeter data. The vial seal perimeter data may represent a plurality of points along at least a portion of a line extending around a perimeter of the vial seal. The system may further include a vial seal three-dimensional data generating module stored in the memory that, when executed by the processor, may cause the processor to generate vial seal three-dimensional data based on the vial seal distance data and the vial seal perimeter data. The system still further includes a vial seal inspection data generating module stored in the memory that, when executed by the processor, may cause the processor to generate vial seal inspection data based on a comparison of the vial seal three-dimensional data to the pre-classified vial seal three-dimensional data. The vial seal inspection data may indicate whether the vial seal includes a vial seal crimp.

[0009] In another embodiment, the vial seal inspection device may include a vial seal distance data generating sensor configured to generate vial seal distance data. The vial seal distance data may represent a plurality of distance measurements correlated to points along a line extending from a top of the vial seal to a bottom edge of the vial seal. The device may also include a vial seal perimeter data input. The vial seal perimeter data input may represent a plurality of points along at least a portion of a line extending around a perimeter of the vial seal. The device may further include a vial seal three-dimensional model generation module stored in the memory that, when executed by the processor, may cause the processor to generate vial seal three-dimensional data based on the vial seal distance data and the vial seal perimeter data.

[0010] In a further embodiment, a non-transitory computer readable medium storing computer readable instructions that, when executed by one or more processors, cause the one or more processors to generate vial seal three-dimensional data may include a vial seal distance data receiving module that, when executed by the processor, may cause the processor to receive vial seal distance data from a vial seal distance data generating device. The vial seal distance data may represent a plurality of distance measurements correlated with points along at least a portion of a line extending from a top of the vial seal to a bottom edge of the vial seal. The computer readable medium may also include a vial seal perimeter data receiving module that, when executed by the processor, may cause the processor to receive vial seal perimeter data. The vial seal perimeter data may represent a plurality of points along at least a portion of a line extending around a perimeter of the vial seal. The computer readable medium may further include a vial seal three-dimensional data generating module that, when executed by the processor, may cause the processor to generate vial seal three-dimensional data based on the vial seal distance data and the vial seal perimeter data.

[0011] The present disclosure will be more fully understood from the following description taken in conjunction with the accompanying drawings, in which: Some of the drawings may be simplified by omitting selected elements to more clearly show other elements. Such omission of elements in some drawings does not necessarily indicate the presence or absence of a particular element in any of the exemplary embodiments, unless expressly indicated in the corresponding written description. Additionally, none of the drawings are necessarily drawn to scale. [Brief description of the drawings]

[0012] [Figure 1] 1 shows an example of a sealed vial with a flip cap. [Figure 2A] 1 shows exemplary components for sealing a vial. [Figure 2B] 1 shows exemplary components for sealing a vial. [Figure 2C] 1 shows exemplary components for sealing a vial. [Diagram 3] 1 illustrates an exemplary system for crimping vial seals using high speed rotating blades. [Figure 4A] 1 illustrates an exemplary vial seal having a damaged rim and a crimped portion. [Figure 4B] 1 illustrates an exemplary vial seal having a recessed peripheral portion. [Figure 4C] 1 illustrates an exemplary vial seal having a crimped portion partially peeled away from a respective peripheral portion. [Figure 4D] 1 illustrates an exemplary vial seal having a loose crimp portion. [Figure 4E] 1 illustrates an exemplary vial seal having misaligned crimp portions. [Figure 4F] 1 illustrates an exemplary vial seal that does not have a crimped portion. [Figure 4G] 1 illustrates an exemplary vial seal having a corrugated crimp portion. [Figure 4H] 1 shows an exemplary vial without a seal. [Figure 5A]1 illustrates an exemplary vial seal having a partial crimped portion. [Figure 5B] 1 illustrates an exemplary vial seal having a partial crimped portion. [Figure 5C] 1 illustrates an exemplary vial seal having a partial crimped portion. [Figure 6A] 1 shows various exemplary vial seals. [Figure 6B] 1 shows various exemplary vial seals. [Figure 6C] 1 shows various exemplary vial seals. [Figure 6D] 1 shows various exemplary vial seals. [Figure 6E] 1 shows various exemplary vial seals. [Figure 6F] 1 shows various exemplary vial seals. [Figure 7] 1 illustrates exemplary vial seal inspection batch data showing vial seal failures using two-dimensional (2D) vial seal crimp inspection. [Figure 8A] 1 illustrates an exemplary vial seal inspection system. [Figure 8B] 1 illustrates an exemplary vial seal inspection system. [Figure 9A] 1 illustrates an exemplary automated visual inspection (AVI) device having two laser triangulation sensors. [Figure 9B] 1 illustrates an exemplary automated visual inspection (AVI) device having two laser triangulation sensors. [Figure 9C] 1 illustrates an exemplary automated visual inspection (AVI) device having two laser triangulation sensors. [Figure 10A] 1 illustrates an exemplary laser triangulation sensor. [Figure 10B] 1 illustrates an exemplary laser triangulation sensor. [Figure 11A] FIG. 1 illustrates a high-level block diagram of an exemplary vial seal inspection system. [Figure 11B] FIG. 1 illustrates a block diagram of an exemplary vial seal inspection sensor. [Figure 11C]1 illustrates an exemplary method for implementing a vial seal inspection sensor. [Figure 11D] FIG. 1 shows a block diagram of an exemplary vial seal inspection device. [Figure 11E] 1 illustrates an exemplary method for implementing a vial seal inspection device. [Figure 11F] 1 illustrates a block diagram of an exemplary remote device. [Figure 11G] 1 illustrates an exemplary method for implementing a remote device. [Figure 12] 1 shows an exemplary three-dimensional representation of a "peeled" vial seal crimp portion. [Figure 13A] 1 illustrates an exemplary three-dimensional model of a damaged seal and seal crimp. [Figure 13B] 1 illustrates an exemplary three-dimensional model of a damaged seal and seal crimp. [Figure 14A] 1 illustrates an exemplary three-dimensional model of a damaged seal. [Figure 14B] 1 illustrates an exemplary three-dimensional model of a damaged seal. [Figure 15] 1 illustrates an exemplary vial seal having a frangible crimp portion. [Figure 16] 1 shows an exemplary vial seal with a missing crimp portion. [Figure 17] A three-dimensional model of the complete 360 ​​degree profile of a vial seal crimp with 0.1 mm resolution is shown. [Figure 18] 13 illustrates an example image generated using distance data associated with vial seal inspection for a vial seal having a blue perimeter. [Figure 19] 1 shows eight example images generated using distance data associated with vial seal inspection for a vial seal having a blue perimeter. [Figure 20A] 13 shows a vial seal 3D model using vial seal distance data generated from a laser triangulation sensor at various exposure levels. [Figure 20B]13 shows a vial seal 3D model using vial seal distance data generated from a laser triangulation sensor at various exposure levels. [Figure 20C] 13 shows a vial seal 3D model using vial seal distance data generated from a laser triangulation sensor at various exposure levels. [Figure 20D] 13 shows a vial seal 3D model using vial seal distance data generated from a laser triangulation sensor at various exposure levels. [Figure 21A] A series of vial profiles are shown with various amounts of sealing material forced under the lip of the vial neck. [Figure 21B] A series of vial profiles are shown with various amounts of sealing material forced under the lip of the vial neck. [Figure 21C] A series of vial profiles are shown with various amounts of sealing material forced under the lip of the vial neck. [Figure 21D] A series of vial profiles are shown with various amounts of sealing material forced under the lip of the vial neck. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Those skilled in the art will appreciate that the elements in the figures are depicted for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions and / or relative positions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of the various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in commercially feasible embodiments are often not shown in order to not overly distract from the views of these various embodiments. Furthermore, it will be appreciated that although certain acts and / or steps may be described or shown in a particular order of occurrence, those skilled in the art will appreciate that such specificity with respect to the order is not actually required. Furthermore, it will be appreciated that although certain acts and / or steps may be described or shown in a particular order of occurrence, those skilled in the art will appreciate that such specificity with respect to the order is not actually required. It will also be appreciated that the terms and expressions used herein have the ordinary technical meanings as given to such terms and expressions by those skilled in the art, as set forth above, unless a different specific meaning is explained herein.

[0014] Detailed Description The devices, systems, and methods of the present disclosure may, for example, inspect a vial seal based on three-dimensional (3D) data representing at least a portion of the vial seal. Vial seal inspection may, for example, be performed in real-time with respect to an associated vial seal crimping process.

[0015] The apparatus, systems, and methods of the present disclosure may include at least one laser triangulation sensor in conjunction with vial seal perimeter data to provide, for example, X-axis data, Y-axis data, and Z-axis data representative of at least a portion of the vial seal. Sealed vials may be rejected with fewer false rejects using the vial seal 3D data compared to vial seal crimp inspection systems based on two-dimensional data. The vial seal perimeter data may be, for example, predetermined (e.g., the vial seal perimeter data may be based on a perimeter length of at least a portion of the vial seal, the vial seal perimeter data may be based on a vial rotation time, etc.). Alternatively or additionally, the vial seal perimeter data may be generated, for example, by a feedback sensor output. The feedback sensor output data (i.e., X-axis data) may be directly correlated with the respective Y-axis data and Z-axis data. More broadly, the Y-axis data and Z-axis data from the vial seal distance data generating sensor may be correlated with the X-axis data representative of points along at least a portion of the vial seal perimeter.

[0016] 1 , the sealed vial 100a may include a vial 105 (e.g., a glass body, etc.) having a central axis 104, a vial stopper 110 (e.g., a rubber seal, etc.), and a vial seal 115 (e.g., an aluminum seal, a metal seal, etc.) having a top surface 118. The vial stopper 110 may be at least partially integral with the vial seal 115. The sealed vial may also include a vial flip cap 125. The vial flip cap 125 may be at least partially integral with the vial seal 115.

[0017] The vial 105 may include a vial neck portion 106 having a vial lip 107 with a vial lip lower surface 108 and a vial lip upper surface 109. The sealed vial 100 may include a vial seal crimping surface 119 that extends at least partially parallel to the lower surface 108 of the vial lip 107 after the vial seal 115 is crimped onto the vial lip 107.

[0018] 2A-2C, components 200a-c for sealing vial 205a may include vial stopper 210a, c, and vial seal 215a-c. Vial 205a may include vial neck portion 206a and vial lip 207a having vial lip lower surface 208a and vial lip upper surface 209a. Vial stopper 210a, c may include vial stopper insert portion 211a, vial stopper lip 212a, vial stopper upper surfaces 213a, 220c, and vial stopper needle insertion regions 214a, 220c. Vial seal 215a-c may include vial seal peripheral surface 216b-c, vial seal lower edge 217b-c, vial seal upper surface 218a-c, vial seal inner surface 221c, and vial seal opening 222c. The vial seal 215b may also include a one-piece vial flip top 225b,c. The vial flip top 225b,c may include a central portion 225b connected via a hinge 226b. The central portion 225b may be flipped over to orientation 227b.

[0019] Turning now to FIG. 3, the vial seal crimping system 300 can include at least one high speed rotating blade 338 .

[0020] For informational purposes, only some details of the vial seal crimping system are included in FIG. 3. The vial seal crimping system 300 may be a mechanical process. A metal blade 338 may move over the vial seal 315 and crimp 324 and bend 323 a portion of the vial seal 315 to form the vial seal crimp 119 around the vial lip underside 108, 208a. Because the vial seal crimping system 300 may include a highly mechanized process combined with current variations in the blade 338 and slight variations in the dimensions of the vial lip 107, 207a, the vial seal crimping system 300 may be prone to defects with very few process adjustments to the crimping process available to reduce these defects. The apparatus, systems, and methods of the present disclosure may incorporate 3D real-time vial seal inspection. 3D vial seal inspection may minimize false rejects while maximizing defect detection compared to 2D based vial seal crimp inspection.

[0021] 4A-H, a defective vial seal 400a-h may include at least one defect 445a-h. FIG. 4E shows a misaligned crimp 445e. FIG. 4F shows a missing crimp 445f. FIG. 4G shows a wavy seal 445g with the associated vial inverted and looking down on the defective vial seal 400g. FIG. 4H shows a missing seal 445h.

[0022] 5A-5C, the defective vial seal 500a-c may include a partial seal crimp 545a-c. As described in detail herein, the devices, systems, and methods of the present disclosure may generate vial seal 3D data that represents at least a portion of the defective vial seal 400a-h, 500a-c.

[0023] 6A-6F, vial seals 600a-f have at least partial crimps 645a-f. FIG. 6B shows vial seal 600b having a loose crimp 645b. FIG. 6C shows vial seal 600c having an intact crimp 645c. While a defective seal crimp does not necessarily affect the quality of the drug enclosed in the container, a vial seal 600a-600f that has been dropped in front of a patient, for example, may render the associated product unreliable.

[0024] Referring to FIG. 7, vial batch data 700 may show vial seal failures from 2D crimp inspection. The associated vial inspection may not detect all actual vial seal defects and may include mostly false failures. Graph 701 shows vial seal inspection resulting from traditional 2D camera inspection (i.e., no Z data as in 3D laser crimp data). The false failures included in graph 70a may tend to cause lighting issues caused by vial seal batch variability. Graph 701 shows that as high as 17% vial seal failure rates were identified using traditional 2D vial seal crimp inspection. The different gray scales in FIG. 7 may reflect different products using vial seal crimping methods that may be similar.

[0025] 8A and 8B, a vial seal inspection system 800a,b may include a vial loading turret 850a,b, a first vial seal inspection device 855a,b, a second vial seal inspection device 856a,b, a first human-machine interface 857a,b, an inspected vial retrieval device 875a,b, and a second human-machine interface 876a,b. The first vial seal inspection device 855a,b and the second vial seal inspection device 856a,b may be configured to provide, for example, twice the vial throughput compared to a single vial seal inspection device. The inspected vial retrieval device 875a may include a tray 877b for accepted vials, a vial discharge conveyor 878a, and a plurality of vial waste bins 879b. The 3D laser head is mounted on the main turret and from a speed and motion standpoint can be considered a camera station, but includes extra data in the Z axis that gives a 3D result.

[0026] 9A-9C, vial seal inspection systems 900a-c may include at least one vial seal inspection device 955a-c having controllers 962a-c with remote device connections 963a-c, user inputs 964a-c, and displays 965a-c. The vial seal inspection devices 955a-c may include mounting bases 958a-c and height adjustable supports 959a-c with pivotally connected vial seal distance data generating sensor brackets 960a-c. The vial seal distance data generating sensor vertical angle 957c may be indicated using angle gauges 961b,c. The vial seal distance data generating sensor vertical angle 957c, 961b,c may represent the angle between a line extending from the vial seal distance data generating sensor near alarm range points 1091a,b to the vial seal distance data generating sensor far alarm range points 1092a,b and the vial central axis 104. The vial seal distance data generating sensor angles 957c, 961b,c may be adjusted manually, for example, to include more or less of either the vial seal circumferential surface 116 or the vial seal crimp surface 119 within the "field of view" of the associated vial seal distance data generating device 980a-c, 981a,b. The vial seal distance data generating sensor angles 957c, 961b,c may be adjusted, for example, to scan the curved surface 323 of the vial seal crimp that passes under the lip 107 and the top portion of the vial seal.

[0027] The vial seal distance data generating devices 980a-c, 981a,b may be configured to use exposure times based on the color and / or texture of the vial seal surfaces 116, 118, 119. Details of the exposure times are provided herein with reference to Table 1.

[0028] The vial seal distance data generating device incidence angles 999a,b may represent, for example, the angle between the central axis 1082a,b of the light emitter and a tangent to a line extending around the perimeter 116. As described in detail herein, the vial seal distance data generating device incidence angles 999a,b may be based on, for example, the color of the surfaces 116, 119, the texture of the surfaces 116, 119, the refractive index associated with coatings on the surfaces 116, 119, etc.

[0029] The vial seal inspection devices 955a-c may include a first vial seal distance data generating device 980a-c configured to generate vial seal distance data representative of at least a portion of the vial seal of the first vial 905b, and a second vial seal distance data generating device 981a,b configured to generate vial seal distance data representative of at least a portion of the vial seal of the second vial 905b. Each vial seal distance data generating device 980a-c, 981a,b may include, for example, a respective laser triangulation device (such as, for example, the laser triangulation devices 1000a,b of FIGS. 10A and 10B). Each vial seal distance data generating device 980a-c, 981a,b may include a vial seal distance data generating device input connection 983c and a vial seal distance data generating device output connection 984c.

[0030] The two vial seal distance data generating devices 980a-c, 981a,b may be configured, for example, to perform a dual vial seal inspection (e.g., 400 vials per minute, etc.). The user interface 964a-c may include, for example, three buttons configured to indicate the height (e.g., standoff heights 1089a,b, etc., in FIGS. 10A and 10B ) of the associated vial seal distance data generating device 980a-c, 981a,b relative to the vial seal crimp 119. This may result in an accurate measurement range 1090a,b. The measurement range 1090a,b may be different for different vial seals 115 (e.g., smaller vial seals, larger vial seals, etc.) and / or different vials 105 (e.g., smaller vials, larger vials, etc.). Additionally, the vial seal inspection devices 955a-c may be configured to have a height threshold for a fail-safe (i.e., if the height 1082a,b is not appropriate for the particular vial being inspected, the vial seal inspection devices 955a-c may issue a warning, shut down the device, etc.).

[0031] During vial seal inspection, the vial seal inspection sensor 980a-c, 981c may not move relative to the vial being inspected (i.e., the vial may rotate relative to the vial seal inspection sensor 980a-c, 981c, etc.). For example, the internal optics of the vial seal inspection sensor 980a-c may scan the entire surface of the vial seal crimping surface 119 and at least a portion of the vial seal circumferential surface 116. Scanning of the vial seal may be performed internally of the vial seal inspection sensor 980a-c, 981c. A predetermined Z-axis "zero" value may be set for heights 1082a,b, for example, by manually turning a knob on the vial seal inspection sensor 980a-c, 981c. The vial seal inspection sensor 980a-c, 981c may be fixed in a specific position relative to a complete vial seal inspection batch. Alternatively or additionally, the Z-axis "zero" value may be automatically and / or dynamically set for heights 1082a,b, for example based on a feedback signal of an associated zero height sensor.

[0032] The standoff height 1089a,b may be set once at the start of a batch by a setup technician. This height may be correlated to, for example, a vial stock keeping unit (SKU). As the main AVI system turret rotates, two new vials enter the inspection area. At this point, the head is stationary and the vials rotate at a preset RPM to allow a pre-defined number of scans to be achieved around the desired vial seal circumference (e.g., 360 degrees, etc.). The vial seal rotation speed and / or number of vial seal scans per rotation may be based, for example, on the vial inspection speed (i.e., vials inspected per second), acceptable Z-axis distance tolerance, desired resolution of the associated vial seal 3D data, etc.

[0033] 10A and 10B, a vial seal distance data generating device 1000a,b (e.g., a laser triangulation sensor, such as the Micro-Epsilon LLT2657-50 laser triangulation sensor available from scancontrol) may include a housing 1080a,b, input / output connections 1083a,b, an output 1065a,b (alternatively or additionally output connection 984c), a light source central axis 1082a,b, light source optics 1085a,b, a light sensor 1086a,b, a light sensor optics 1087a,b, a scan line angle 1088a,b, a standoff height 1089a,b, a measurement range 1090a,b, a near alarm 1091a,b, and a far alarm 1092a,b. The vial seal distance data generating devices 1000a,b may be configured to output vial seal distance data representing, for example, Y data values ​​that are correlated with Z axis data.

[0034] Although not shown in Figures 10A and 10B, the vial seal distance data generating device 1000a,b may also include a memory (e.g., memory 1182a in Figure 11A) and / or a processor (e.g., processor 1181a in Figure 11A). The vial seal distance data generating device 1000a,b with memory 1182a and processor 1181a may be configured to process the Y-axis data and the Z-axis data and then provide the processed Y-axis data and / or the processed Z-axis data to the vial seal distance data generating device controller 962a-c. The vial seal distance data generating device 1000a,b may be configured to output, for example, a binary indication of whether a given vial seal is acceptable or not. Alternatively or additionally, the vial seal distance data generating device 1000a, b may be configured to output, for example, a continuous range of values ​​(e.g., 0 to 100%, greater than 0 percent to less than 100 percent, etc.) indicating the probability (likelihood) of whether a given vial seal is acceptable.

[0035] Using two vial seal distance data generating devices 1000a,b, the associated vial seal inspection system 800a,b may be configured to inspect, for example, 4cc and 5cc vial sizes at a rate of 400 vials per minute, 20cc and 30cc vial sizes at a rate of 333 vials per minute, and 50cc vial sizes at a rate of approximately 200 vials per minute. The scan rates may be based on the respective resolution.

[0036] The laser beams 1082a,b are projected onto the vial seal 115 to be measured and a portion of the laser beam may be reflected through an optical system onto detectors 1086a,b. As the distance from the vial seal distance data generating device 1000a,b to the vial seal 115 (i.e., the Z-axis distance) changes, the laser beams 1082a,b move proportionally onto detectors 1086a,b which focus the beams to calculate the relative distance to the vial seal which is correlated with the respective Y-axis data.

[0037] The number of scans per period may be predetermined. The specifications of the vial sealing distance data generating device 1000a,b may include the scanning speed. To accomplish one scan, the laser may send out the laser beam 1082a,b over the vertical (Y-axis) area of ​​one scan. The vial sealing distance data generating device 1000a,b may then wait for the laser light to return to the light sensor 1086a,b. The vial sealing distance data generating device 1000a,b may perform calculations (e.g., triangulation calculations, etc.) regarding the depth (Z-axis). The light emission, light sensing, and distance calculations may be performed at the speed of light. The vial sealing distance data generating device 1000a,b may be selected for the color of the vial sealing surface 116 (e.g., gray vial sealing surface 116, blue vial sealing surface 116, etc.).

[0038] 11A, a vial seal inspection system 1100a may include a vial seal inspection device 1155a having at least one vial seal distance data generating device 1180a (e.g., a laser triangulation sensor, a sonic sensor, etc.) and a remote device 1150a communicatively interconnected via a network 1140a. The vial seal inspection system 1100a may be similar to, for example, the vial seal inspection system 800a, b of FIG. 8A and FIG. 8B. The vial seal distance data generating device 1180a may be similar to, for example, the vial seal distance data generating sensor 1000a, b or the vial seal distance data generating device 900a-c of FIG. 10. The remote device 1150a may be similar to, for example, any one of the man-machine interfaces 857a, b or 876a, b of FIG. 8A and FIG. 8B.

[0039] For clarity, only one vial seal inspection device 1155a, one vial seal distance data generating device 1180a, and one remote device 1150a are shown in Figure 11A. Although Figure 11A shows only one vial seal inspection device 1155a, one vial seal distance data generating device 1180a, and one remote device 1150a, it should be understood that any number of vial seal inspection devices 1155a, vial seal distance data generating devices 1180a, and remote devices 1150a may be supported by the vial seal inspection system 1100a.

[0040] The vial seal inspection device 1155a may include a memory 1162a and a processor 1161a for storing and executing, respectively, a module 1163a. ​​The module 1163a may be stored in the memory 1162a as a set of computer readable instructions and associated with an application for implementing at least a portion of the vial seal inspection system 1100a. As described in more detail herein, the processor 1161a may execute the module 1163a to cause the processor 1161a to, among other things, receive, generate, and / or transmit data (e.g., vial seal inspection sensor configuration data, vial seal inspection device configuration data, vial seal 3D data, etc.) to and from the remote device 1150a.

[0041] Vial seal inspection device 1155a may also include a user interface 1157a, which may be any type of electronic display device, such as a touch screen display, a liquid crystal display (LCD), a light emitting diode (LED) display, a plasma display, a cathode ray tube (CRT) display, or any other type of known or suitable electronic display along with a user input device. User interface 1157a may present a user interface display, which may, for example, show a user interface for an implementation of at least a portion of vial seal inspection system 1100a.

[0042] The vial seal inspection device 1155a may also include a vial rotational position input 1131a, a network interface 1156a, and an interface 1164a configured to communicate, for example, vial seal inspection sensor configuration data, vial seal distance data, vial seal 3D data, etc., using, for example, a vial seal distance data generating sensor 1180a. The network interface 1156a may be configured to facilitate communication between, for example, the vial seal inspection device 1155a and the network device 1140a, via any wireless communication network 1141a, including, for example, wireless LAN, MAN or WAN, WiFi, TLS v1.2 WiFi, the Internet, or any combination thereof. Additionally, the fixed telepresence device 205a may be communicatively connected to any other device via any suitable communication system, for example, any publicly available or privately owned communication network, including those using wireless communication structures, such as wireless LAN and WAN, wireless communication networks including satellite and cellular telephone communication systems.

[0043] The vial seal distance data generating device 1180a may be similar to the vial seal distance data generating sensor 1000a, b of Figures 10A and 10B, for example. As described with reference to Figures 10A and 10B, the vial seal distance data generating device 1180a may include a memory 1182a and a processor 1181a for storing and executing a module 1183a, respectively. The module 1183a may be stored in the memory 1182a as a set of computer readable instructions and may relate to an application for implementing at least a portion of the vial seal inspection system 1100a. As described in more detail herein, the processor 1181a may execute the module 1183a to cause the processor 1181a to, among other things, receive, generate, and / or transmit data (e.g., camera control data, mobile base control data, video data, etc.) directly with the vial seal inspection device 1155a and / or with the remote device 1150a.

[0044] The vial seal distance data generating device 1180a may also include a user interface 1165a, which may be any type of electronic display device, such as a touch screen display, a liquid crystal display (LCD), a light emitting diode (LED) display, a plasma display, a cathode ray tube (CRT) display, or any other type of known or suitable electronic display along with a user input device. The user interface 1165a may present a user interface display, which may, for example, show a user interface for an implementation of at least a portion of the vial seal inspection system 1100a.

[0045] The vial seal distance data generating device 1180a may also include a light source output 1184a, a light sensor input 1186a, and an interface 1185a configured to communicate, for example, vial seal inspection sensor configuration data, vial seal distance data, vial seal 3D data, etc., with the vial seal inspection device 1155a. Additionally, the vial seal distance data generating device 1180a may be communicatively connected to any other device via any suitable communication system, such as any publicly available or privately owned communication network, including those using wireless communication structures such as wireless LANs and WANs, wireless communication networks including satellite and cellular telephone communication systems.

[0046] The remote device 1150a may include a memory 252a and a processor 251a for storing and executing, respectively, a module 253a. The module 253a may be stored in the memory 1152a as a set of computer readable instructions and associated with an application for implementing at least a portion of the vial seal inspection system 1100a. As described in more detail herein, the processor 1151a may execute the module 1153a to cause the processor 1151a to, among other things, receive, generate, and / or transmit data to and from the network device 1140a (e.g., vial seal distance data sensor configuration data, vial seal distance data device configuration data, vial seal inspection data, vial seal distance data, vial seal 3D data, etc.).

[0047] The remote device 1150a may also include a user interface 1154a, which may be any type of electronic display device, such as a touch screen display, a liquid crystal display (LCD), a light emitting diode (LED) display, a plasma display, a cathode ray tube (CRT) display, or any other type of known or suitable electronic display along with a user input device. The user interface 1154a may present a user interface display that may, for example, present a user interface for an implementation of at least a portion of the vial seal inspection system 1100a.

[0048] The remote device 1150a may also include a network interface 257a configured to facilitate communication between the remote device 1150a and the network device 1140a (e.g., vial seal distance data sensor configuration data, vial seal distance data device configuration data, vial seal inspection data, vial seal distance data, vial seal 3D data, etc.) via any wireless communication network 1142a including, for example, TLS v1.2 REST API, TLS v1.2 Cellular, CSV / JSON output, TLS v1.2 REST API, wireless LAN, MAN or WAN, WiFi, TLS v1.2 WiFi, the Internet, or any combination thereof. Additionally, the remote device 1150a may be communicatively connected to any other device via any suitable communication system, such as any publicly available or privately owned communication network, including those using wireless communication structures such as wireless LAN and WAN, wireless communication networks including satellite and cellular telephone communication systems.

[0049] 11B, a vial seal inspection system 1100b may include a vial seal distance data generating device 1180b having a user interface generating module 1183b, a vial seal inspection configuration data generating module 1184b, a vial seal inspection configuration data receiving module 1185b, a laser control data generating module 1186b, a laser sensor data receiving module 1187b, a vial rotational position data receiving module 1188b, a vial seal inspection data generating module 1189b, a vial seal inspection data storage module 1190b, and a vial seal inspection data transmitting module 1191b, stored in a memory 1182b as a set of computer readable instructions, for example. In any case, modules 1183b-1191b may be similar to module 1183a of FIG. 11A, for example.

[0050] 11C, a method for implementing the vial sealing distance data generating device 1100c may be implemented, for example, by a processor (e.g., processor 1181a of FIG. 11A) executing at least a portion of modules 1183b-1191b of FIG. 11B. In particular, processor 1181a may execute user interface generating module 1183b to cause processor 1181a to generate, for example, a user interface (block 1183c).

[0051] The processor 1181a may execute the vial seal inspection configuration data generation module 1184b to cause the processor 1181a to generate, for example, vial seal inspection configuration data (block 1184c). The vial seal inspection configuration data may include one or more of a vial ID, a vial seal ID, a vial seal distance data generating device ID, a vial seal crimping system ID, a Z-axis tolerance threshold (e.g., near alarms 1091a, b, far alarms 1092a, b, etc.), an X-axis measurement range, a Y-axis measurement range, a Z-axis measurement range, a vial seal distance data generating sensor standoff height, a vial seal distance data generating sensor exposure time, a vial seal distance data generating sensor scan rate, a vial seal distance data generating sensor incidence angle, a vial seal distance data generating sensor vertical angle, a vial rotation rate, a vial physical dimension, a vial seal physical dimension, a vial seal surface texture, a vial seal surface color, a vial seal surface coating thickness, a vial seal surface coating material, etc. The processor 1181a may execute the vial seal inspection configuration data receiving module 1185b to cause the processor 1181a to receive, for example, vial seal inspection configuration data (block 1185c).

[0052] The processor 1181a may execute the laser control data generating module 1186b to cause the processor 1181a to generate, for example, laser control data (block 1186c). For example, the processor 1181a may generate the laser control data based on an exposure time of the vial sealing distance data generating sensor, a scanning speed of the vial sealing distance data generating sensor, etc. The processor 1181a may execute the laser sensor data receiving module 1187b to cause the processor 1181a to receive, for example, laser sensor data (block 1187c). For example, the processor 1181a may receive laser sensor data from the light sensors 1186a,b.

[0053] The processor 1181a may execute the vial rotational position data receiving module 1188b to cause the processor 1181a to receive, for example, vial rotation data (block 1188c). The vial seal rotational position data (i.e., vial seal perimeter data, X-axis data, etc.) may be, for example, predetermined (e.g., the vial seal perimeter data may be based on a circumferential length of at least a portion of the vial seal, the vial seal perimeter data may be based on a vial rotation time, etc.) or may be manually input via the user interface 1165a. Alternatively or additionally, the vial seal rotational position data may be generated, for example, by a feedback sensor output. The feedback sensor output data (i.e., X-axis data) may be directly correlated with the respective Y-axis data and Z-axis data. More broadly, the processor 1181a may generate the vial seal 3D data based on correlating the Y-axis data and Z-axis data from the vial seal distance data generating sensor with the X-axis data, which may represent points along at least a portion of the perimeter of the vial seal.

[0054] The processor 1181a may execute the vial seal inspection data generation module 1189b to cause the processor 1181a to generate, for example, vial seal inspection data (block 1189c). The vial seal inspection data may represent, for example, Y-axis data, Z-axis data, vial seal 3D data, vial seal acceptable, vial seal bad, a probability that the vial seal is acceptable, a probability that the vial seal crimp is acceptable, etc. Additionally or alternatively, the processor 1181a may generate the vial seal inspection data based on a comparison of the current Z-axis value to a Z-axis tolerance threshold.

[0055] The processor 1181a may execute a vial seal inspection data storage module 1190b to cause the processor 1181a to store, for example, the vial seal inspection data (block 1190c). The processor 1181a may execute a vial seal inspection data transmission module 1191b to cause the processor 1181a to transmit, for example, the vial seal inspection data (block 1191c). For example, the processor 1181a may transmit the vial seal inspection data to the remote device 1150a and / or the vial seal inspection device 1155a.

[0056] 11D, a vial seal inspection system 1100d may include a vial seal inspection device 1155d having a user interface generating module 1163d, a vial seal inspection configuration data generating module 1164d, a vial seal inspection configuration data receiving module 1165d, a vial rotational position data receiving module 1166d, a vial seal inspection data generating module 1167d, a vial seal inspection data storage module 1168d, and a vial seal inspection data transmitting module 1169d, stored in a memory 1162d as a set of computer readable instructions, for example. In any case, modules 1163d-1169d may be similar to, for example, module 1163a of FIG.

[0057] 11E, a method of implementing a vial seal inspection device may be performed, for example, by a processor (e.g., processor 1161a of FIG. 11A) executing at least a portion of modules 1163d-1169d of FIG. 11D. In particular, processor 1161a may execute user interface generation module 1163d to cause processor 1161a to generate, for example, a user interface (block 1163e).

[0058] Processor 1161a may execute vial seal inspection configuration data generation module 1164d to cause processor 1161a to generate vial seal inspection configuration data (block 1164e), for example. The vial seal inspection configuration data may include one or more of a vial ID, a vial seal ID, a vial seal distance data generating device ID, a vial seal crimping system ID, a Z-axis tolerance threshold (e.g., near alarms 1091a, b, far alarms 1092a, b, etc.), an X-axis measurement range, a Y-axis measurement range, a Z-axis measurement range, a vial seal distance data generating sensor standoff height, a vial seal distance data generating sensor exposure time, a vial seal distance data generating sensor scan rate, a vial seal distance data generating sensor incidence angle, a vial seal distance data generating sensor vertical angle, a vial rotation rate, a vial physical dimension, a vial seal physical dimension, a vial seal surface texture, a vial seal surface color, a vial seal surface coating thickness, a vial seal surface coating material, etc.

[0059] The processor 1161a may execute the vial seal inspection configuration data receiving module 1165d to cause the processor 1161a to receive, for example, vial seal inspection configuration data (block 1165e). For example, the processor 1161a may receive vial seal inspection configuration data from the remote device 1150a.

[0060] The processor 1161a may execute the vial rotational position data receiving module 1166d to cause the processor 1161a to receive, for example, vial rotational position data (block 1166e). The vial seal rotational position data (i.e., vial seal perimeter data, X-axis data, etc.) may be, for example, predetermined (e.g., the vial seal perimeter data may be based on a circumferential length of at least a portion of the vial seal, the vial seal perimeter data may be based on a vial rotation time, etc.) or may be manually input via the user interface 1157a. Alternatively or additionally, the vial seal rotational position data may be generated, for example, by a feedback sensor output. The feedback sensor output data (i.e., X-axis data) may be directly correlated with the respective Y-axis data and Z-axis data. More broadly, the processor 1161a may generate the vial seal 3D data based on correlating the Y-axis data and Z-axis data from the vial seal distance data generating sensor with the X-axis data, which may represent points along at least a portion of the perimeter of the vial seal.

[0061] Processor 1161a may execute vial seal inspection data generation module 1167d to cause processor 1161a to generate, for example, vial seal inspection data (block 1167e). The vial seal inspection data may represent, for example, Y-axis data, Z-axis data, vial seal 3D data, vial seal acceptable, vial seal bad, a probability that the vial seal is acceptable, a probability that the vial seal crimp is acceptable, etc. Additionally or alternatively, processor 1161a may generate the vial seal inspection data based on a comparison of the current Z-axis value to a Z-axis tolerance threshold.

[0062] The processor 1161a may execute a vial seal inspection data storage module 1168d to cause the processor 1161a to store, for example, the vial seal inspection data (block 1168e). The processor 1161a may execute a vial seal inspection data transmission module 1169d to cause the processor 1161a to transmit, for example, the vial seal inspection data (block 1169e).

[0063] 11F, a vial seal inspection system 1100f may include a remote device 1150f having a user interface generation module 1153f, a vial seal inspection configuration data generation module 1154f, a vial seal inspection configuration data transmission module 1155d, a vial seal inspection data generation module 1156f, a vial seal inspection data storage module 1157f, and a vial seal inspection data transmission module 1158f, stored in memory 1162d, for example, as a set of computer readable instructions. In any event, modules 1153f-1158f may be similar to module 1153a of FIG. 11A, for example.

[0064] 11G, a method for implementing remote device 1100g may be implemented by a processor (e.g., processor 1151a of FIG. 11A) executing, for example, at least a portion of modules 1153f-1158f of FIG. 2F. In particular, processor 1151a may execute user interface generation module 1153f to cause processor 1151a to generate, for example, a user interface (block 1153g).

[0065] Processor 1151a may execute vial seal inspection configuration data generation module 1154f to cause processor 1151a to generate, for example, vial seal inspection configuration data (block 1154g). The vial seal inspection configuration data may include one or more of a vial ID, a vial seal ID, a vial seal distance data generating device ID, a vial seal crimping system ID, a Z-axis tolerance threshold (e.g., near alarms 1091a, b, far alarms 1092a, b, etc.), an X-axis measurement range, a Y-axis measurement range, a Z-axis measurement range, a vial seal distance data generating sensor standoff height, a vial seal distance data generating sensor exposure time, a vial seal distance data generating sensor scan rate, a vial seal distance data generating sensor incidence angle, a vial seal distance data generating sensor vertical angle, a vial rotation rate, a vial physical dimension, a vial seal physical dimension, a vial seal surface texture, a vial seal surface color, a vial seal surface coating thickness, a vial seal surface coating material, etc. The processor 1151a may execute a vial seal inspection configuration data transmission module 1155f to cause the processor 1151a to transmit, for example, the vial seal inspection configuration data to the vial seal inspection sensor 1180a or the vial seal inspection device 1155a (block 1155g).

[0066] Processor 1151a may execute vial seal inspection data receiving module 1156f to cause processor 1151a to receive, for example, vial seal inspection data (block 1156g). For example, process 1151a may receive vial seal inspection data from vial seal inspection sensor 1180a or vial seal inspection device 1155a. The vial seal inspection data may represent, for example, Y-axis data, Z-axis data, vial seal 3D data, vial seal acceptable, vial seal bad, a probability that the vial seal is acceptable, a probability that the vial seal crimp is acceptable, etc. Additionally or alternatively, processor 1151a may generate vial seal inspection data based on a comparison of the current Z-axis value to a Z-axis tolerance threshold.

[0067] The processor 1151a may execute a vial seal inspection data analysis module 1158f to cause the processor 1151a to, for example, analyze the vial seal inspection data (block 1158g). For example, the processor 1151a may determine a number of false rejects based on the vial seal inspection data. The processor 1151a may execute a vial seal inspection data storage module 1157f to cause the processor 1151a to, for example, store the vial seal inspection data in a vial seal inspection database 1156a (block 1158g).

[0068] 12, a "peel back image" of a 360 degree 3D profile view of the vial seal 1200 is shown. The grayscale in the image represents Z-axis data. For example, the vial seal crimp portion 1218 represents the crimp that orbits the vial lip 107. The processor 1181a may generate vial seal 3D data representing the vial seal defect 1245. Additionally or alternatively, the processor 1181a may generate vial seal 3D data representing the vial seal crimp angle (or how crimped the vial seal actually is) based on the X-axis data, the Y-axis data, and the Z-axis data. The processor 1181a may generate vial seal 3D data representing the vial seal top portion 1210 and / or the vial seal periphery 1216 based on the X-axis data, the Y-axis data, and the Z-axis data.

[0069] 13A and 13B, a three-dimensional model 1300a,b of a vial seal can include vial seal perimeter surfaces 1316a,b, vial seal bottom edges 1317a,b, vial seal crimp surfaces 1318a,b, vial seal crimp angles 1319a,b, and damaged vial seal regions 1345a,b. The three-dimensional model 1300a,b and / or damaged vial seal regions 1345a,b can be based on, for example, X-axis data, Y-axis data, and Z-axis data.

[0070] 14A and 14B, a three-dimensional model 1400a,b of a vial seal can include vial seal perimeter surfaces 1416a,b, vial seal bottom edges 1417a,b, vial seal crimp surfaces 1418a,b, vial seal crimp angles 1419a,b, and damaged vial seal areas 1445a,b (e.g., damaged seal perimeters, etc.). The three-dimensional model 1400a,b and / or the damaged vial seal areas 1445a,b can be based on, for example, X-axis data, Y-axis data, and Z-axis data.

[0071] 15, a three-dimensional model 1500 of a vial seal may include a vial seal perimeter 1516, a vial seal bottom edge 1517, a vial seal crimp surface 1518, a vial seal crimp angle 1519, and a damaged vial seal area 1545 (e.g., a weak vial seal crimp, etc.). The three-dimensional model 1500 and / or the damaged vial seal area 1545 may be based on, for example, X-axis data, Y-axis data, and Z-axis data. A vial seal crimp inspection based on a 2D image may yield a large number of erroneous results associated with a weak vial seal crimp compared to a vial seal crimp inspection based on vial seal 3D data. The vial seal 3D may represent, for example, a vial seal crimp angle 1519.

[0072] 16, a three-dimensional model 1600 of a vial seal may include a vial seal perimeter 1616, a vial seal bottom edge 1617, a vial seal crimp surface 1618, a vial seal crimp angle 1619, and a damaged vial seal area 1645 (e.g., a missing vial seal crimp, etc.). The three-dimensional vial seal model 1600 and / or the damaged vial seal area 1645 may be based on, for example, X-axis data, Y-axis data, and Z-axis data. A vial seal crimp inspection based on a 2D image may yield a large number of false results related to a missing vial seal crimp compared to a vial seal crimp inspection based on vial seal 3D data. A missing vial seal crimp may be considered a significant defect that is detected with greater accuracy using vial seal 3D data. For example, a straight edge 1617 may indicate, for example, no crimp and that something happened during the associated vial seal crimping process and / or with the associated blade.

[0073] 17, a three-dimensional vial seal model 1700 of a vial seal can include a vial seal perimeter 1716, a vial seal bottom edge 1717, a vial seal crimp surface 1718, a vial seal crimp angle 1719, and a damaged vial seal area 1745 (e.g., uneven vial crimp angle, etc.). The three-dimensional vial seal model 1700 and / or the damaged vial seal area 1745 can be based on, for example, X-axis data, Y-axis data, and Z-axis data. The remote device 1150a can store, for example, vial seal 3D data that represents a complete 360-degree profile of the vial seal crimp, for example, down to a resolution of 0.1 mm. After scanning at least one vial seal crimp surface and acquiring a full 3D 360 degrees representative of the vial seal crimp, the remote device may, for example, determine whether the vial seal crimp has failed or may determine a probability of whether the vial seal crimp is acceptable. In either case, the vial seal inspection system 1100a may detect larger defects based, for example, on a comparison of the Z-axis data to near alarms 1091a,b and / or far alarms 1092a,b.

[0074] For smaller vials with vial seal crimp defects, the vial seal inspection system 1100a may include over 300 scans or lines of the vial seal crimp surface based on which it may generate over 300 consecutive vial seal crimp radius angles. The vial seal 3D data representing the vial seal parameters 1719 is particularly useful for detecting defective vial seal crimp radii. The vial seal 3D data representing the vial seal crimp radii may be used to adjust the vial seal inspection system 1100a to detect, for example, loose vial seal crimps. Vial seal crimp inspection based on 2D images may not be effective for detecting loose vial seal crimps. That is, while lighting changes may cause false rejects in the 2D data, for the vial seal inspection system 1100a, the lighting may have substantially no effect on, for example, the vial seal Z-axis distance measurements. The vial seal inspection system 1100a may receive the actual Z-axis measurements and calculate the vial seal crimp radius based on the corresponding Z-axis data.

[0075] A thin colored surface (e.g., 5 μm plastic cover, blue coating, etc.) may be added to the vial seal outer surface 116, 118, 119. The vial seal 3D data may be based on the vial seal inspection configuration data, for example, as shown in Table 1. Table 1 includes ten possible scan speeds for the vial seal distance data generating device 1180b. The scan speeds may be set once and then used for the complete vial inspection batch. For example, in configuration 2 comparison #, the vial seal inspection system 1100a may provide 326 scans or 326 lines across a 360 degree vial seal crimp, providing a resolution of 0.142 mm for smaller vials (resolution for 4 cc) and 0.217 mm for larger vials (resolution for 50 cc). Since vial seal defects may be on the order of a few millimeters, the vial seal distance data generating device 1180a may be configured to have a resolution as shown in Table 1. Vial seal distance data generating device configuration 2, as shown in bold in Table 1, may work particularly well with vial seal 115 having a blue vial seal periphery.

[0076] [Table 1]

[0077] The vial seal distance data received from the corresponding vial seal distance data generating sensor 1080a may represent a scan or line and may be used to generate a complete 3D image of multiple scans, as shown in Table 1. For example, for a 4cc vial from Table 1, the 3D data of the vial seal has 328 lines.

[0078] 18, dead spot 1801 represents an area on an associated vial seal 115 where an associated vial seal distance data generating sensor 1180a did not receive a reading. The variation between areas 1802 and 1803 represents the variation of the vial seal surfaces 116, 118, 119.

[0079] 19, vial seal 3D data 1900 may represent, for example, eight different scans 1901-1908 of a vial seal that are aligned in time and starting point. Dead spots 1801 may cause excessive vial seal inspection errors.

[0080] As shown, eight images 1901-1908 show patterns that result in dead spots 1801. The dead spots 1801 can vary due to the color of the vial seal cover, surface texture, slight variations in the rotational movement of the vial, etc.

[0081] 20A-20D, vial seal 3D models 2000a-d represent vial seal 3D data obtained from vial seal distance data generating device 1180a at various exposure levels. As shown, false rejects can be reduced by increasing the exposure time. Dead spots 1801 can be generated by decreasing the exposure time. Vial seal distance data generating device 1180a can be configured to have a resolution based on the color and / or texture of the vial seal surface. For example, the thickness of the thin film on the surface of the vial seal can be about 5 microns (which is a typical value for anodized aluminum coating of a vial seal). The vial seal distance data generating sensor can be configured to have an angle of incidence of, for example, 20 degrees, the refractive index of the thin film can be about 1.5, and a wavelength of 658 nm, the minimum thickness required to produce destructive interference (black spots in the image) can be determined. For example, the displacement d of the laser beam 1082a,b within the coating may be equal to one-quarter of the wavelength in the medium plus k times the wavelength itself (i.e., d=(λ / n) / 4+k(λ / n)). At an incidence angle of 20°, (λ / n) / 4, the thickness change may result in destructive interference approximately equal to 105 nm+k(210 nm). As a specific example, a monotonic change in thickness of less than 1 micron may result in four fringes.

[0082] The 3D system can be installed, for example, in a qualified visual inspection system within a computer network (such as system 1100a of FIG. 11A).

[0083] 21A-21D, a series of vial profiles 2100a, 2100c, and 2100d show various amounts of sealing material (e.g., metal, etc.) in the form of crimps 2145a, 2145c, and 2145d pressed under the lip of the vial neck. Vials 2100a, 2100c, and 2100d show a gradual decrease in crimp level. The laser crimp inspection system of FIGS. 9A-11G, for example, can provide physical dimensional readings of crimp levels 2145a, 2145c, and 2145d. In FIG. 21B and a detailed view of FIG. 21B, vial 2100a of FIG. 21A includes crimp 2145a, which has been pressed with an amount of material (e.g., metal, etc.) that would be found under the vial neck of a typical well sealed vial. Laser systems 900a-11G may detect / measure dimensions of crimps 2145a, 2145c, 2145d (marked "A" in FIG. 21A), for example, to determine the crimp level and identify if there are sub-optimal seals and sealing defects. For example, in FIG. 21C and FIG. 21D, vials 2100c and 2100 include reduced crimp levels 2145c and 2145d compared to crimp 2145a, and thus the laser crimp inspection system of FIG. 9A-11G may, for example, consider these to be sub-optimal seals and sealing defects. That is, in FIG. 21C and FIG. 21D, crimps 2145c and 2145d include a push-in amount (i.e., associated crimp dimension A) that is seen to gradually decrease to the point where any seal intended to be created by the crimp may be compromised.

[0084] The devices, systems, assemblies, components, subsystems, and methods have been described in terms of exemplary embodiments, but are not limited thereto. The detailed description should be construed as merely exemplary and does not describe every possible embodiment of the present disclosure. Many alternative embodiments can be implemented using either current technology or technology developed after the filing date of this patent, but such embodiments still fall within the scope of the claims that define the invention disclosed herein.

[0085] Those skilled in the art will understand that various modifications, alterations and combinations may be made to the above-described embodiments without departing from the spirit and scope of the present invention disclosed herein, and that such modifications, alterations and combinations are to be construed as being within the scope of the present invention.

Claims

1. 1. A vial seal inspection system comprising: a vial seal distance data generation device configured to generate vial seal distance data, the vial seal distance data representing a plurality of distance measurements correlated to points along at least a portion of a line extending from a top edge of the vial seal to a bottom edge of the vial seal; a vial seal perimeter data generation device configured to generate vial seal perimeter data, the vial seal perimeter data representing a plurality of points along at least a portion of a line extending around a perimeter of the vial seal; a vial seal three-dimensional data generation module stored in a memory that, when executed by a processor, causes the processor to generate vial seal three-dimensional data based on the vial seal distance data and the vial seal periphery data; a vial seal inspection data generation module stored in a memory that, when executed by a processor, causes the processor to generate vial seal inspection data based on a comparison of the vial seal three-dimensional data with pre-classified vial seal three-dimensional data, the vial seal inspection data indicating whether the vial seal includes a vial seal crimp; Vial seal inspection system.

2. The system of claim 1 , wherein the vial seal distance data generating device includes at least one laser triangulation sensor.

3. 2. The system of claim 1, further comprising a vial seal distance data generating sensor angle manual adjustment mechanism, wherein the vial seal distance data generating sensor angle is manually adjusted to include more or less of either the vial seal circumferential surface or the vial seal crimping surface within the measurement range.

4. The system of claim 1, wherein the vial seal distance data generating sensor vertical angle represents the angle between a line extending from the vial seal distance data generating sensor near alarm distance point to the vial seal distance data generating sensor far alarm distance point and the vial central axis.

5. 10. The system of claim 1, wherein the vial seal distance data generating sensor angle is configured to scan a curved surface of the vial seal crimp that extends below the vial lip.

6. 2. The system of claim 1, further comprising: a vial sealing distance data generating device configuration data receiving module stored in memory that, when executed by a processor, causes the processor to receive vial sealing distance data generating device configuration data, the vial sealing distance data generating device configuration data representing at least one of a sensor standoff height, a sensor exposure time, and a scan speed.

7. The system of claim 1 , wherein the vial seal inspection data represents Z-axis data associated with at least one surface of a vial seal.

8. 1. A vial seal inspection device comprising: a vial seal distance data generating sensor configured to generate vial seal distance data, the vial seal distance data representing a plurality of distance measurements correlated to points along at least a portion of a line extending from a top edge of the vial seal to a bottom edge of the vial seal; a vial seal perimeter data input, the vial seal perimeter data input representing a plurality of points along at least a portion of a line extending around a perimeter of the vial seal; a vial seal three-dimensional model generation module stored in a memory that, when executed by a processor, causes the processor to generate vial seal three-dimensional data based on the vial seal distance data and the vial seal periphery data; a vial seal inspection device comprising:

9. The device of claim 8 , wherein the vial seal distance data generating sensor includes at least one laser triangulation sensor.

10. The device of claim 8 , wherein the vial seal three-dimensional data represents at least one surface of a vial seal.

11. The device of claim 8 , wherein the vial seal three-dimensional data represents at least one surface of a vial seal crimp.

12. The device of claim 8 , wherein the vial seal three-dimensional data represents a radius of curvature of a vial seal crimp portion.

13. 9. The device of claim 8, further comprising a vial sealing distance data generating device configuration data receiving module stored in memory that, when executed by a processor, causes the processor to receive vial sealing distance data generating device configuration data, the vial sealing distance data generating device configuration data representing at least one of a sensor standoff height, a sensor exposure time, and a scan speed.

14. The telepresence device of claim 8 , further comprising a vial seal perimeter distance data receiving module stored in memory that, when executed by a processor, causes the processor to receive vial seal perimeter distance data.

15. The telepresence device of claim 14 , wherein the vial seal perimeter distance data is predetermined.

16. A non-transitory computer-readable medium storing computer-readable instructions that, when executed by one or more processors, cause the one or more processors to generate vial seal three-dimensional data, the non-transitory computer-readable medium comprising: a vial seal distance data receiving module that, when executed by a processor, causes the processor to receive vial seal distance data from a vial seal distance data generating device, the vial seal distance data representing a plurality of distance measurements correlated to points along at least a portion of a line extending from a top edge of the vial seal to a bottom edge of the vial seal; a vial seal perimeter data receiving module that, when executed by a processor, causes the processor to receive vial seal perimeter data, the vial seal perimeter data representing a plurality of points along at least a portion of a line extending around a perimeter of the vial seal; a vial seal three-dimensional data generation module that, when executed by a processor, causes the processor to generate vial seal three-dimensional data based on the vial seal distance data and the vial seal periphery data; 1. A non-transitory computer-readable medium comprising:

17. 17. The computer-readable medium of claim 16, further comprising: a vial sealing distance data generating device configuration data receiving module that, when executed by a processor, causes the processor to receive vial sealing distance data generating device configuration data, the vial sealing distance data generating device configuration data representing at least one of a sensor standoff height, a sensor exposure time, and a scan speed.

18. 17. The computer readable medium of claim 16, further comprising a vial seal perimeter distance data receiving module stored in the memory that, when executed by a processor, causes the processor to receive vial seal perimeter distance data.

19. 20. The computer-readable medium of claim 18, wherein the vial seal circumference distance data is based on a vial rotation speed.

20. The computer-readable medium of claim 16, wherein the vial seal distance data generating sensor vertical angle represents the angle between a line extending from the vial seal distance data generating sensor near alarm range point to the vial seal distance data generating sensor far alarm range point and the vial central axis.

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