Mimic AVI Imaging for Offline Inspection Line Troubleshooting
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Solution Overview
Problem
Existing automated visual inspection (AVI) systems for pharmaceutical products are large, complex, and costly, requiring lengthy downtimes for troubleshooting and new product characterization, which disrupts production and is inefficient.
Innovation Solution
A mimic AVI station is constructed to replicate the performance of existing AVI stations, allowing offline troubleshooting and characterization, using techniques such as reverse engineering, 3D scanning, and image comparison tools to ensure accurate replication of hardware and software components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If troubleshooting and characterization are performed on existing AVI stations, then problem resolution and product qualification can be achieved, but production downtime increases and productivity decreases
Solution Approach 1:
The patent creates a mimic AVI station that replicates the functionality and inspection capabilities of the original AVI station. This copy allows all troubleshooting, characterization, and qualification activities to be performed on the mimic station instead of the production line equipment, thereby eliminating the need to shut down production equipment for these activities. The mimic station includes replicated imaging systems, lighting, and inspection algorithms to accurately simulate the original station's performance.
Solution Approach 2:
The patent separates the troubleshooting and characterization functions from the production inspection function by creating a dedicated mimic AVI station. This segmentation allows the production AVI station to operate continuously without interruption while the mimic station handles all diagnostic, development, and qualification tasks independently.
2Ease of operation
If additional AVI line equipment is purchased for troubleshooting and characterization, then offline development can be performed, but cost increases significantly
Solution Approach 1:
Instead of purchasing entirely new AVI equipment for offline development, the patent creates a mimic station that replicates only the essential inspection functions needed for troubleshooting and characterization. This approach uses a subset of the full production equipment capabilities, reducing the overall cost while still providing adequate offline development functionality.
Solution Approach 2:
The mimic AVI station is designed to perform multiple functions including troubleshooting, characterization, qualification, and validation of inspection algorithms. This multi-functionality eliminates the need for separate dedicated equipment for each of these activities, thereby reducing overall equipment costs while maintaining comprehensive offline development capabilities.
3Measurement precision
If the mimic AVI station replicates hardware and software components accurately, then troubleshooting accuracy improves, but device complexity increases
Solution Approach 1:
The patent replicates only the essential imaging and inspection components needed for accurate troubleshooting, rather than copying the entire production AVI system in its full complexity. The mimic station focuses on replicating the critical path elements that affect inspection accuracy while simplifying or omitting non-essential production-specific hardware and software components.
Data Source
AI summary
In a method for replicating performance of an automated visual inspection (AVI) station, a mimic AVI station that performs one or more AVI functions of the AVI station is constructed. One or more container images are captured by an imaging system of the AVI station while a container is illuminated by an illumination system of the AVI station, and one or more additional container images are captured by a mimic imaging system of the mimic AVI station. The method also includes identifying, by one or more processors, one or more differences between the one or more additional container images and the one or more container images, generating, by the one or more processors, a visual indication of the difference(s) and/or one or more suggestions for modifying the mimic AVI station, and modifying the mimic AVI station based on the visual indication.