In-Process Image-Based Quality Control for Punch Tool Verification
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Solution Overview
Problem
Existing methods for in-process quality control of manufacturing tools and products, such as punch tools in pharmaceutical processes, are prone to human errors and require complex setups, manual calibration, and involve multiple components, leading to inefficiencies and inaccuracies.
Innovation Solution
A quality control module that uses a camera, database, and machine-learning to compare real-time images of objects with reference images, determining compliance without manual input, and outputs results through a user interface, optionally with mixed-reality guidance, using sensors for distance and surface mapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods are used to verify punch tool dimensions, then the process is simple to set up, but human errors occur and measurement precision deteriorates
Solution Approach 1:
The patent uses optical copying to create digital images of the punch tool and its engravings. A camera captures the punch surface, and software processes these images to extract dimensional information, replacing manual visual inspection with automated optical copying and image analysis.
Solution Approach 2:
The patent replaces manual mechanical measurement methods (using calipers or rulers) with an automated optical-mechanical system. The camera module and processing software automatically capture and analyze punch dimensions, eliminating the need for manual mechanical measurement tools and operations.
2Measurement precision
If automated measurement devices are positioned on the tool, then measurement precision improves, but the device complexity increases and setup time increases
Solution Approach 1:
The patent creates a universal verification system that can measure multiple types of punch tools with different dimensions and engravings using the same camera module and software. The system adapts to different punch types through software configuration rather than requiring physical reconfiguration, enabling multi-functionality without increasing hardware complexity.
Solution Approach 2:
The system uses digital copying of punch engravings and surfaces through camera imaging, replacing the need for physical measurement devices that must be mounted and configured. The digital copies are processed automatically, eliminating setup and dismount time while maintaining measurement precision.
3Adaptability or versatility
If multiple individual components and instruments are used, then measurement capability is comprehensive, but device complexity increases and ease of operation deteriorates
Solution Approach 1:
The patent merges the camera module, image processing software, database storage, and verification logic into a single integrated quality control system. This unified system replaces multiple separate measurement instruments and manual processes, making the system easier to operate while maintaining comprehensive measurement capabilities through software-based adaptability.
Solution Approach 2:
The integrated system is designed to be universal, capable of verifying different types of objects (punches, tablets, capsules) through software configuration rather than requiring separate specialized instruments for each object type. This multi-functionality simplifies operation while maintaining comprehensive verification capability.
4Reliability
If manual recording of quality control data is performed, then the process is simple, but reliability deteriorates due to human errors
Solution Approach 1:
The system performs self-service by automatically capturing images, processing them to extract measurement data, comparing results against specifications, and generating verification reports without human intervention. This automated self-service eliminates human errors in data recording while the software handles all complex processing tasks.
Solution Approach 2:
The patent replaces manual data recording and processing with automated optical-mechanical systems and software algorithms. The camera captures data, software processes images and extracts measurements, and the system automatically generates results, eliminating the manual recording process and its associated errors.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to an in-process quality control module (13) for controlling the quality of an object (2), said quality control module (13) being configured to receive an input allowing to determine the type of object (2) to analyze, determine the type of object (2) using said received input, retrieve from the database (12) the reference images corresponding to the determined type of object (2), receive images generated by a camera module (111), compare said received images with the retrieved reference images, determine that the object (2) is compliant with the determined type of object (2) when the received images of the sequence match with the retrieved reference images, output on the user interface (112) of the control device (13) that the object (2) is compliant or not compliant.