Empty Flexible Container Optical Inspection for Particulate Detection
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Solution Overview
Problem
Existing methods for detecting visible particulate matter in flexible solution containers, such as IV fluid and dialysis fluid bags, are inadequate, often relying on inefficient manual inspection and failing to detect defects with high accuracy, leading to increased costs and risks due to product recalls.
Innovation Solution
An automated visual inspection system using a light source, detector, and image processor to analyze images of empty flexible containers, identifying particulate matter by illuminating the containers against a backdrop and employing image processing to determine defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual human visual inspection is used to detect particulate matter, then physical interaction with container closure is avoided, but inspection efficiency is low and detection probability is only 70 percent
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system that uses a light source, detector, and image processor to detect particulate matter in flexible containers, eliminating the need for human physical interaction while significantly improving both detection probability and inspection efficiency
Solution Approach 2:
The system creates an optical copy (image) of the container contents by transmitting light through the flexible container and capturing the transmitted light with a detector, allowing automated analysis of the container contents without direct physical contact
2Productivity
If high-speed production lines are used to meet customer demand, then productivity increases, but the proportion of defective containers increases due to manufacturing defects
Solution Approach 1:
The inspection system performs defect detection early in the manufacturing process while containers are still empty and on the production line, allowing defective containers to be identified and removed before they proceed further down the line, thereby maintaining high productivity while reducing the proportion of defective products
3Measurement precision
If light is transmitted through empty flexible containers for inspection, then particulate matter detectability is improved, but inspection system complexity increases
Solution Approach 1:
The inspection system uses a multi-functional integrated design where a single optical path serves multiple purposes: illuminating the container, transmitting through it, and being detected to create an image, thereby achieving high detectability while minimizing the number of separate components needed
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 significantly improves the detectability and sensitivity of particulate matter, reducing inspection time, minimizing container deformation, and preventing product recalls by detecting defects early in the manufacturing process, thus enhancing manufacturing efficiency and reducing waste.
Implementation Method 1
The light source is configured to transmit light through the at least one empty, flexible container
Implementation Method 2
the detector is configured to receive the light and generate image data
Implementation Method 3
the light source includes at least one filter configured to tune the light source to emit light at the predetermined wavelength
Data Source
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Figure 2
AI summary
An automated visual inspection system for detecting the presence of particulate matter includes an empty, flexible container, a light source, a detector, and an image processor. The light source is configured to transmit light through the container towards the detector, and the detector is configured to receive the light and generate image data. The image processor is configured to analyze the image data, determine whether the empty, flexible container is defective, and generate a rejection signal if the empty, flexible container is defective.