Camera-Based Drug Container Inspection System
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Solution Overview
Problem
Current quality control inspection methods for drug containers are slow and wasteful, often resulting in the unnecessary discard of containers and drug products due to the tedious nature of liquid rinsing and filtering, which can lead to false positives and limited inspection capacity.
Innovation Solution
An inspection system utilizing a camera device coupled with a robot that captures series of images of the interior surfaces of drug containers, processed by a control circuit to identify foreign matter, allowing for non-contact, automated inspection and reducing the risk of artefacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If liquid rinsing and filtering method is used for inspection, then foreign matter can be detected, but inspection speed is slow and productivity is limited
Solution Approach 1:
The patent replaces the mechanical liquid rinsing and filtering system with an optical imaging system using a camera device. The camera captures images of the container interior surface, and a control circuit processes these images to detect foreign matter, eliminating the need for physical rinsing and filtering operations while maintaining detection capability and significantly improving inspection speed
Solution Approach 2:
The patent creates an optical copy (image) of the container interior surface instead of physically interacting with it through rinsing. The camera device captures visual information that replicates the appearance of the interior surface, allowing foreign matter detection through image analysis rather than physical filtration
2Measurement precision
If liquid rinsing method is used for inspection, then foreign matter can be identified, but false positives occur and containers are unnecessarily discarded
Solution Approach 1:
The patent replaces the liquid rinsing method with an optical imaging and image processing system. The control circuit analyzes captured images to distinguish actual foreign matter from artifacts or rinsing residues, providing more accurate identification and reducing false positives that lead to unnecessary container discards
Solution Approach 2:
The patent introduces an intermediary image processing step between the inspection action and the detection result. The control circuit processes the captured images to differentiate between genuine foreign matter and artifacts caused by the inspection process itself, thereby reducing false positives
3Measurement precision
If manual inspection method is used, then detailed examination is possible, but the process is tedious and time-consuming
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical imaging system. The camera device captures high-resolution images of the container interior, and the control circuit automatically processes these images to identify foreign matter, eliminating the tedious manual examination process while maintaining or improving inspection detail capability
Solution Approach 2:
The patent enables the inspection system to perform self-service through automation. The camera device and control circuit work together to automatically capture, process, and analyze images without human intervention, eliminating the time-consuming manual inspection process while maintaining detailed examination capability
4Productivity
If camera-based inspection is implemented, then inspection speed increases, but system complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where a single camera device performs multiple functions: capturing images, providing illumination through integrated light sources, and enabling various inspection angles through robotic positioning. This universal approach increases inspection speed while managing system complexity through functional integration rather than multiple separate components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables faster inspection of more containers, reduces false positives, and minimizes the discard of both containers and drug products, improving quality control and compliance by effectively identifying foreign matter without the need for fluid rinsing.
Implementation Method 1
a camera device (14) having a lens (38)... configured to capture a series of images of an interior surface of a sidewall and/or bottom wall of the drug container
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
An inspection system for a drug container is provided to identify foreign matter, such as particles or fibers, within the drug container prior to filling with a drug. The system includes a camera device aligned with an axis of the drug container and captures a series of images of an interior surface of a sidewall of the drug container while the robot causes relative movement between the drug container and the camera device along a linear path. Atypical lighting, which improves contrast between particles and the background in images is employed to aid detection. A control circuit then processes the series of images to identify foreign matter within the drug container.