Image-Based Quality Control Module for Punch Tool Compliance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for in-process quality control of manufacturing tools, such as punch tools in pharmaceutical processes, are prone to human errors and require complex setups, manual calibration, and involve multiple instruments, 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 includes a scanner for object identification and sensors for distance and surface mapping, enabling rapid and reliable assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods (Vernier Caliper) or sophisticated instruments are used to verify punch tool size, then measurement precision is improved, but device complexity and ease of operation deteriorate due to complex setup, manual calibration, and multiple instruments required
Solution Approach 1:
The patent combines multiple verification functions (size measurement, surface texture recording, compliance determination) into a single integrated device that captures images of the punch tool and compares them against reference images stored in a database, eliminating the need for multiple separate instruments and manual calibration procedures
Solution Approach 2:
The patent replaces manual mechanical measurement methods (Vernier Caliper) and complex sophisticated instruments with an image-based optical system that uses camera capture and digital image comparison to verify punch tool dimensions and characteristics, significantly simplifying the verification process
2Ease of operation
If manual recording methods are used for in-process quality control data, then ease of operation is maintained, but reliability deteriorates due to human errors in recording
Solution Approach 1:
The system performs automatic data capture and recording through image acquisition and automated comparison with reference images, eliminating the need for manual data entry while ensuring high reliability through objective digital analysis rather than human judgment
Solution Approach 2:
The system provides immediate feedback by comparing captured images against stored reference images and automatically determining compliance, creating a closed-loop verification process that eliminates delays and errors associated with manual recording and review
3Measurement precision
If sophisticated instruments are used for quality control verification, then measurement precision is improved, but productivity deteriorates due to high set-up/dismount time
Solution Approach 1:
The system performs preliminary actions by storing reference images in a database before the actual verification process, allowing for rapid comparison and decision-making during production without requiring time-consuming setup or dismount procedures
Solution Approach 2:
The system enables dynamic verification by allowing operators to quickly switch between different punch tool types by selecting from stored reference images in the database, facilitating rapid adaptation to different production requirements without physical reconfiguration
Data Source
AI summary
The invention relates to an in-process quality control module that controls the quality of an object. The quality control module receives an input allowing to determine the type of object to analyze, determines the type of object using the received input, retrieves from the database the reference images corresponding to the determined type of object, receives images generated by a camera module, compares the received images with the retrieved reference images, determines that the object is compliant with the determined type of object when the received images of the sequence match with the retrieved reference images, and outputs on the user interface of the control device that the object is compliant or not compliant.