Optical Semi-Quantitative Capsule Filling Check
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Solution Overview
Problem
Current methods for monitoring the filling of capsules with powdered medicaments are either expensive, inefficient, or unable to provide precise 100% quality assurance, particularly for small filling quantities, and are often cumbersome, posing health risks due to incomplete or incorrect filling.
Innovation Solution
A method involving digital imaging and analysis to record and evaluate the filling compound within capsules, using electronic cameras and optics to capture and assess the contour and shape of the filling material, allowing for quick and precise qualitative and quantitative evaluation of the filling, even for small volumes, without disrupting the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If random sampling methods are used for quality assurance, then production speed is maintained, but measurement precision and reliability of quality control deteriorate
Solution Approach 1:
The patent replaces mechanical weighing systems with optical measurement systems. Light beams are transmitted through the capsule filling material, and the attenuation of light intensity is measured to determine filling quantity. This substitution enables non-contact, high-speed optical measurement that maintains production speed while improving measurement precision and enabling 100% inspection of all capsules.
Solution Approach 2:
The patent creates an optical copy or representation of the filling material's physical properties by measuring light attenuation. Instead of directly weighing the physical capsule, the system measures the optical properties (light intensity transmission) as a proxy for filling quantity, enabling rapid non-contact measurement that preserves production speed while enhancing measurement capability.
2Productivity
If optical transillumination methods are used, then inspection speed is improved, but measurement precision deteriorates for small filling quantities
Solution Approach 1:
The patent changes the measurement parameter from simple light presence/absence to quantitative light intensity attenuation measurement. By measuring the degree of light intensity reduction as it passes through the capsule, the system can precisely determine small filling quantities. This parameter change enables the optical method to achieve both high inspection speed and high measurement precision, even for small filling amounts.
3Reliability
If 100% inspection is implemented, then quality assurance reliability is improved, but production time increases
Solution Approach 1:
The patent replaces time-consuming mechanical weighing operations with rapid optical measurement. The optical system can measure light attenuation instantaneously as capsules pass through the inspection station, enabling 100% inspection of all capsules without slowing down the production line. This substitution eliminates the time loss associated with traditional weighing methods while maintaining comprehensive quality assurance.
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
Enables rapid and accurate 100% inspection of capsule fillings, reducing the risk of health hazards by ensuring precise filling quantities, while being cost-effective and easily integratable into existing systems, even for high-speed production processes.
Implementation Method 1
the capsules are fed individually via a loading path to a test station, where they enter an electromagnetic radiation field that is generated by coherent, polarized light. The device includes an optical sensor to collect the light on the other side of the capsule
Data Source
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AI summary
The invention relates to a method for monitoring the filling of a capsule with a medicament, a corresponding filing method and the corresponding devices. According to the monitoring method, after at least part of the capsule is filled with a given filling mass of given closed shape of medicament, in a first step, at least the filling mass located in the part of the capsule after filling is recorded with a digital image, in a second step, the shape of the filling mass located in the part of the capsule is determined from the digital image and, in a third step, the shape analysed to give an analysis of the filling in comparison with given shapes.