Filler Inspection Imaging in High-Heat Humidity Enclosures
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Solution Overview
Problem
Existing inspection methods for filler devices in high-temperature, high-humidity environments fail to detect defects such as loss or discoloring of components or foreign matter adherence, and image capture devices are prone to malfunction in such conditions.
Innovation Solution
An inspection device with image capture devices enclosed in durable boxes and supplied with fresh air to prevent exposure to high-temperature, high-humidity environments, allowing for image data capture and analysis of filler machine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image capture device is used to inspect filler machine, then inspection precision is improved, but device reliability deteriorates in high-temperature high-humidity environment
Solution Approach 1:
The inspection device is divided into separate functional modules: the image capture device is isolated from the filler machine inspection area by a transparent partition wall. This segmentation allows the image capture device to be protected from the harsh high-temperature high-humidity environment while still enabling it to capture images of the filler machine components for inspection purposes.
Solution Approach 2:
A transparent partition wall serves as an intermediary barrier between the image capture device and the filler machine. This partition allows optical transmission (images to be captured) while physically separating the image capture device from the harmful steam and moisture in the sterilization environment, thus protecting the device without compromising inspection capability.
2Reliability
If transparent box is used to protect image capture device, then device reliability is improved, but measurement precision deteriorates due to impaired image quality
Solution Approach 1:
The partition wall is designed with different properties in different regions: the portion facing the image capture device is made transparent to allow clear image formation, while the portion facing the filler machine area provides protective functionality. This local differentiation of material properties allows the same structure to simultaneously ensure both protection and image quality.
Solution Approach 2:
The transparent partition wall creates an optical copy or reflection of the filler machine components that the image capture device can detect. By using the transparent material, the system creates a visible copy of the inspected object that maintains sufficient quality for inspection while the physical barrier provides environmental protection.
3Reliability
If manual visual check is performed by worker, then reliability is improved for detecting defects, but productivity deteriorates due to inspection time
Solution Approach 1:
The manual visual inspection process is replaced with an automated image capture and analysis system. The image capture device electronically captures images of filler machine components, and these images are processed (presumably by image processing software) to automatically detect defects such as foreign matter adherence or component loss, eliminating the need for manual visual checks by workers.
Solution Approach 2:
The inspection system performs self-inspection by automatically capturing and analyzing images of the filler machine components. The system monitors itself and the filler machine without requiring human intervention, continuously detecting defects and providing automated inspection results that improve both reliability and productivity.
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 reliable detection of defects in filler machines by generating high-quality image data, even in harsh conditions, facilitating timely maintenance and preventing product contamination.
Implementation Method 1
an air supply source configured to supply air into the box
Data Source
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AI summary
To provide an inspection device configured to determine whether a filler device has any visually recognizable abnormality and capable of normal operation even when the inspection device is in a high-temperature, high-humidity environment, an inspection device is configured to inspect an inspection target based on image data and includes: an image capture device 2 configured to capture an image of an inspection target to generate image data; a box 3 containing the image capture device 2; and an air supply source 4 configured to supply air into the box 3.