Automated Visual Inspection Plunger Depth Measurement
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Solution Overview
Problem
Traditional automated visual inspection (AVI) systems face challenges in accurately measuring the depth of plungers in syringes due to uneven syringe flanges, dust, debris, tray defects, and plunger dimples, leading to incorrect identification of the top edge and improper rejection of tested vessels.
Innovation Solution
The AVI system employs image processing techniques such as blob analysis, pixel dilation, hole-filling, erosion, and template-matching algorithms to identify the uppermost edge of the syringe flange and plunger, using a linear motorized system to incrementally advance vessels and perform one-dimensional edge detection to ensure accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional edge detection techniques are used to identify the top edge of the syringe flange, then the measurement process is simple, but the identification accuracy deteriorates due to uneven flange shapes, dust, debris, and tray defects
Solution Approach 1:
The patent divides the image processing into distinct stages: initial edge detection to locate the flange region, followed by separate processing to identify and remove artifacts (dust, debris, tray defects), and finally precise top edge identification. This segmentation allows each stage to focus on specific tasks, improving overall accuracy without requiring a single overly complex algorithm.
Solution Approach 2:
The patent introduces intermediate processing steps that act as mediators between the raw image and the final measurement. These include artifact detection and removal procedures that clean the image data before the final edge identification, effectively filtering out interfering elements like dust and tray defects that would otherwise compromise measurement accuracy.
2Adaptability or versatility
If a fixed region of interest (ROI) is used for plunger edge detection, then the processing is straightforward, but the system can only test a single size and type of syringe, reducing adaptability
Solution Approach 1:
The patent implements dynamic ROI adjustment that adapts to different syringe sizes and types. Instead of using a fixed ROI, the system dynamically determines the appropriate ROI boundaries based on the detected flange position and syringe characteristics. This allows the same system to accommodate multiple syringe varieties while maintaining processing efficiency through automated parameter adjustment.
3Measurement precision
If conventional image processing techniques are used, then the system is easy to operate, but plunger depth measurements are inaccurate due to incorrect top edge identification
Solution Approach 1:
The patent performs preliminary actions to prepare the image data before the final measurement calculation. This includes initial edge detection to establish the flange position, artifact identification and removal, and verification steps that ensure the top edge is correctly identified. These preliminary processing steps automatically handle the complexity, maintaining ease of operation while significantly improving measurement accuracy.
Data Source
AI summary
An automated visual inspection (AVI) system is described to measure the depth of plungers positioned within vessels. The AVI system implements various types of image processing as well as other techniques to identify, for a vessel, a reference point and the uppermost edge of the plunger. Because different inconsistencies and/or artifacts may be introduced within the vessel image, different processing techniques may be executed on the region containing the reference point versus the plunger region. In doing so, the AVI system provides a robust means to accurately measure plunger depth that is highly resilient to the aforementioned artifacts and consistently measures plunger depth for a wide variety and types of vessels.