Multi-head Fiber Optic Scanner for Sealed Sterile Packaging Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods are inadequate for detecting micro defects and embedded objects in sealed sterilized packaging, as conventional optical inspection systems struggle with high magnification requirements and impractical image processing times, and existing fiber optic systems are not suitable for real-time defect detection in non-flat packaging areas.
Innovation Solution
A multi-head fiber optic scanner with linear fiber optic arrays distributed along sealing paths allows for high-resolution, parallel image processing of packaging regions using a single camera, enabling effective detection of defects and contamination with angled fiber optic sensors to cover larger detection widths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional optical inspection systems increase magnification to detect micro defects, then object resolution is improved, but camera field area decreases resulting in impractical images and long processing time
Solution Approach 1:
The inspection system divides the packaging surface into multiple regions and uses multiple cameras positioned at different locations to capture parallel images of these regions simultaneously. Each camera captures a specific zone with appropriate magnification, avoiding the need to capture the entire large area at high magnification which would result in impractical images and long processing times.
Solution Approach 2:
The system transitions from a single-camera sequential inspection approach to a multi-camera parallel inspection approach by adding the spatial dimension of multiple inspection points. This allows simultaneous capture of multiple regions at high resolution, reducing processing time while maintaining detection precision.
2Measurement precision
If conventional optical inspection systems increase magnification to detect micro defects, then object resolution is improved, but the system complexity increases
Solution Approach 1:
The inspection system divides the packaging surface into multiple regions and uses multiple cameras positioned at different locations to capture parallel images of these regions simultaneously. Each camera captures a specific zone with appropriate magnification, avoiding the need to capture the entire large area at high magnification which would result in impractical images and long processing times.
Solution Approach 2:
The system introduces an image processing module as an intermediary that receives images from multiple cameras and integrates them into a comprehensive inspection result. This intermediary component simplifies the overall system by centralizing the complex image processing tasks rather than requiring complex synchronized capture and processing across multiple independent inspection points.
3Measurement precision
If fiber optic bundles are used for optical transmission, then image quality is improved, but scanning speed decreases making real-time defect detection impossible
Solution Approach 1:
The inspection system divides the packaging surface into multiple regions and uses multiple cameras positioned at different locations to capture parallel images of these regions simultaneously. Each camera captures a specific zone with appropriate magnification, avoiding the need to capture the entire large area at high magnification which would result in impractical images and long processing times.
Solution Approach 2:
The system transitions from a single-camera sequential inspection approach to a multi-camera parallel inspection approach by adding the spatial dimension of multiple inspection points. This allows simultaneous capture of multiple regions at high resolution, reducing processing time while maintaining detection 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
This solution provides efficient, real-time detection of defects and contamination in sealed sterilized packaging, improving quality control with reduced equipment costs and eliminating the need for multiple cameras, while maintaining high resolution and practical image processing times.
Implementation Method 1
Each column (or row) provides a remote optical transmission of light illumination from the scanned area
Data Source
AI summary
An inspection station identifies defects such as artifacts (e.g., dust, hair, particles) in the sealing areas of sealed sterile packages. A multi-head optical scanner can include at least two fiber optic sensors each comprised of a bundle of optical fibers arranged into a linear face coupled to an image processing module and oriented towards a scanning area of sealed packages moving through a conveyance system. An image processing module can analyze input from the at least two fiber optic sensor arrangements to identify artifacts in the sealing areas of the sealed packages.