Batch Vial Inspection with Stationary Imaging and Spinning Holders

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Solution Overview

Problem

Conventional automated inspection tools for parenteral drugs in prefilled glass containers are costly, complex, and require a large footprint due to the spinning turret and camera tracking mechanisms, which increase complexity and cost.

Innovation Solution

An inspection tool with a motor-driven system that moves carts holding vials to a stationary inspection position, where each vial is spun on its own axis and imaged by a camera, using a maglev or conveyor system to facilitate efficient and compact batch inspection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a spinning turret with camera tracking is used for inspection, then inspection speed is improved, but device complexity and cost increase

Engineering Contradiction:

Improveinspection speedVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Instead of spinning the turret and tracking the containers with cameras, the patent inverts the approach by keeping the turret stationary and spinning the individual containers on their own axes. This eliminates the need for complex camera tracking mechanisms while maintaining high-speed inspection capability

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent divides the inspection system into multiple independent container holders that can spin individually rather than using a single large spinning turret. Each container is inspected independently while others are being loaded or unloaded, enabling parallel processing and maintaining high productivity without requiring a large spinning mechanism

Inventive Principle:

Principle #1Segmentation

2Productivity

If a spinning turret with camera tracking is used for inspection, then inspection speed is improved, but cost increases

Engineering Contradiction:

Improveinspection speedVSAvoidcost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent eliminates expensive camera tracking systems by inverting the conventional approach - instead of tracking moving containers with spinning turrets, stationary cameras inspect containers that spin on their own axes. This significantly reduces system cost while maintaining inspection speed

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent uses simpler, less expensive container holders that can be easily replaced or cleaned compared to complex spinning turret mechanisms. The design prioritizes cost-effective components that can be manufactured more simply and maintained more easily

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If a spinning turret is used for inspection, then inspection capacity is improved, but footprint increases

Engineering Contradiction:

Improveinspection capacityVSAvoidfootprint

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The patent segments the inspection system into multiple small container holders arranged in a compact configuration rather than requiring a large spinning turret. This allows high inspection capacity through parallel processing of multiple containers while maintaining a small overall footprint

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent utilizes vertical space and multi-layer arrangements of container holders to increase inspection capacity without expanding the horizontal footprint. Containers are arranged in multiple levels or radial positions around a compact central axis

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If conventional inspection tools are used, then inspection capability is provided, but maintenance difficulty increases

Engineering Contradiction:

Improveinspection capabilityVSAvoidmaintenance difficulty

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent divides the inspection system into modular, independently replaceable components including container holders, cameras, and lighting units. This segmentation allows easy maintenance and repair of individual modules without affecting the entire system, improving ease of repair while maintaining inspection capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stationary camera design with containers spinning in place allows for easier access to cameras and lighting components for maintenance, as they remain in fixed positions rather than requiring disassembly of complex spinning mechanisms

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12560552B2Compact apparatus for batch vial inspection

Publication Date: 2026.02.24 APPLIED MATERIALS INC

AI summary

Methods and apparatus of inspection tools for inspecting impurities in vials are provided herein. In some embodiments, an inspection tool for inspecting impurities in vials includes: a motor; a plurality of carts configured to move via the motor to selectively place each of the plurality of carts in an inspection position, wherein each of the plurality of carts includes a vial holder configured to hold a plurality of vials, and wherein each vial holder is configured to spin the plurality of vials on their own respective axes; and a camera configured to take an image of at least one of the plurality of vials of a corresponding cart of the plurality of carts when the corresponding cart is disposed in the inspection position.