Blister Pack Inspection Reference Setup for Defect Detection
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Solution Overview
Problem
Existing inspection systems for blister machines in the pharmaceutical industry are prone to human error due to manual data input, leading to potential issues in identifying defects in blister pack production, which can have serious consequences and increase production downtime.
Innovation Solution
An automated method for configuring an inspection system that uses electronic references and image analysis to determine geometric and color data of blister packs, reducing reliance on manual input and enhancing the system's accuracy in detecting defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual data input is used for inspection system calibration, then the system can be configured, but human error increases leading to reduced reliability
Solution Approach 1:
The inspection system automatically extracts data from electronic references and images without requiring manual user input. The system self-configures by processing document data, images, and comparing them to generate reference data, eliminating human error in data entry while maintaining ease of operation through automated workflows.
2Measurement precision
If automated image analysis is implemented, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent replaces manual mechanical data entry with automated optical and electronic systems. Image capture devices photograph physical documents and blister packs, while software automatically extracts data through pattern recognition and comparison algorithms, achieving high precision without proportionally increasing operational complexity.
Solution Approach 2:
The system creates digital copies of physical documents and products through imaging. These copies are then processed automatically by comparing extracted data from electronic references with image data, enabling precise measurement without requiring complex manual analysis procedures.
3Reliability
If comprehensive reference data is collected, then inspection reliability improves, but loss of time during configuration increases
Solution Approach 1:
The system performs preliminary data collection by capturing images and extracting information from electronic references before actual inspection begins. Reference data is pre-processed and stored, allowing rapid comparison during production without time-consuming manual configuration during operation.
Solution Approach 2:
The patent combines multiple data sources including electronic reference documents, captured images, and extracted data into a unified reference data set. This integration consolidates configuration steps and enables comprehensive inspection capabilities without proportionally increasing configuration time.
Data Source
AI summary
There is provided a method for configuring an inspection system of a blister machine for producing blister packs comprising pharmaceutical products, the method comprising, obtaining, by the inspection system, an electronic reference comprising first data associated with a blister pack, analysing, by the inspection system, the electronic reference to extract the first data, obtaining, by the inspection system, a reference image comprising an image of a portion of an unsealed bottom film of the blister pack comprising one or more pockets in which pharmaceutical product is located, comparing, by the inspection system, the first data with the reference image, determining, by the inspection system and based on the comparing, second data associated with the pharmaceutical product, and generating, by the inspection system, reference data comprising the first data and the second data, the reference data for use by the inspection system to identify issues during operation of the blister machine.