Color-Based Pill Counting with LED Illumination and Camera Detection
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Solution Overview
Problem
Existing pill dispensing systems are unreliable and require adjustments for different pill sizes and shapes, leading to inaccuracies in automated or semi-automated pharmaceutical dispensing, which can result in serious errors.
Innovation Solution
A standardized module with a plurality of individual cells, each with a screw-type feed and dispensing mechanism, controlled by a main processor, allowing for varying speeds and handling of diverse pill sizes and shapes without mechanical adjustments, combined with a color-based counting system using a housing with LEDs and a color camera for accurate counting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional photoelectric counting systems are used, then counting speed can be maintained, but reliability deteriorates due to inability to handle diverse pill sizes and shapes without adjustments
Solution Approach 1:
The system divides the counting task into multiple perspectives by using both a top-down camera view and a side photoelectric sensor view. The top camera captures images of pills from above, while the side sensor detects pills passing through a beam, creating segmented detection zones that together provide reliable counting for diverse pill types without requiring mechanical adjustments.
Solution Approach 2:
A translucent tray is introduced as an intermediary element between the light source and the camera. This tray allows light to pass through while providing a structured surface for pill placement, enabling the top camera to clearly capture pill images and the side sensor to detect pill passage, thereby mediating between the counting requirements and diverse pill characteristics.
2Ease of operation
If standardized dispensing cells are used, then ease of operation improves, but device complexity increases due to electronic control systems
Solution Approach 1:
The standardized dispensing cell is designed as a universal unit that can handle multiple types of pills (different sizes, shapes, and quantities) without requiring mechanical adjustments. Each cell is equipped with electronic controls that automatically adapt to the prescribed quantity, making a single cell design serve multiple functions across different dispensing scenarios.
Solution Approach 2:
The system replaces traditional mechanical adjustment mechanisms with electronic control systems. The microprocessor-controlled cell dispenser uses electronic signals to adjust dispensing parameters, timing, and sequencing, eliminating the need for manual mechanical adjustments while maintaining ease of operation through software-based configuration.
3Productivity
If high-speed dispensing is implemented, then productivity increases, but measurement precision may deteriorate due to reduced detection time
Solution Approach 1:
The system performs preliminary actions by capturing a top-down image of all pills in the well before dispensing begins. This pre-counting step establishes the total quantity, and the system then coordinates the dispensing sequence to match this predetermined count, allowing high-speed operation while maintaining precision through advance measurement and coordinated execution.
Solution Approach 2:
The system uses feedback from the top camera to verify pill placement and quantity before dispensing. The microprocessor receives image data, counts the pills, and uses this feedback information to control the dispensing sequence, ensuring that the high-speed mechanical dispensing accurately reflects the measured quantity without losing measurement precision.
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
The system provides reliable, accurate, and high-speed counting and dispensing of pills, tablets, and capsules, enhancing throughput and safety in pharmaceutical facilities by eliminating the need for adjustments and ensuring precise counting and identification.
Implementation Method 1
A housing has a plurality of light sources, such as LEDs, disposed in or proximate the housing for generating electromagnetic radiation
Implementation Method 2
A color camera is mounted on the housing and above the removable translucent tray
Data Source
AI summary
A low profile, color-based counting system. A housing has a light source, such as a matrix of LEDs, preferably disposed in the housing for generating electromagnetic radiation upwardly. A removable, translucent tray is disposed above the light source. A second light source can be added above the tray, directing light downwardly thereto. A color camera is mounted on the housing and above the removable translucent tray.