Laser Profilometer for Encapsulated Vial Closure Defect Detection
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Solution Overview
Problem
Existing methods for inspecting vial closures, particularly encapsulated vials, are inadequate as they fail to detect defects such as nicks in the capsule's lower skirt, and require complex computational processes or physical contact, making them inefficient for large-scale production.
Innovation Solution
A method using a laser profilometer to scan the capsule and vial profiles in two or three dimensions, calculating parameters like closure circumference diameter, angle of intersection, and distance from the lower skirt to the vial neck, without physical contact, and employing different exposure times to account for varying materials' optical properties, allowing for precise defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If optical inspection devices are used to evaluate closure position, then inspection automation is improved, but defect detection capability deteriorates because they cannot detect capsule defects like nicks
Solution Approach 1:
The patent replaces traditional optical inspection systems with a laser profilometer-based measurement system. Instead of using cameras and image processing to detect closure position, the invention uses a laser profilometer to scan the capsule and vial profiles, obtaining precise dimensional data about the closure assembly including the capsule, cap, and their relative positions. This substitution enables both automation and reliable detection of defects like nicks that optical systems miss.
2Device complexity
If traditional optical methods are used for inspection, then device complexity is reduced, but measurement precision deteriorates because they cannot detect subtle defects in the capsule
Solution Approach 1:
The patent changes the measurement parameters from simple optical presence/position detection to precise dimensional parameter measurement. The laser profilometer measures specific parameters including the closure circumference diameter, angle of intersection between capsule surfaces, and distance from the lower skirt to the vial neck. By measuring these specific dimensional parameters with high precision, the system can detect subtle defects like nicks and improper encapsulation that traditional optical methods cannot identify.
3Reliability
If complex computational processes are used for image processing, then defect detection capability is improved, but productivity deteriorates due to increased processing time
Solution Approach 1:
The patent extracts only the essential measurement data needed for defect detection by using a laser profilometer to directly scan and measure critical dimensions of the capsule and vial. Instead of capturing and processing complex images, the system extracts precise dimensional parameters (closure circumference, intersection angles, distances) directly through laser scanning. This extraction approach provides sufficient defect detection capability while avoiding the time-consuming image processing required by camera-based systems, thereby maintaining high 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 efficient, non-contact detection of defects in vial closures across the entire perimeter, improving inspection quality and reducing computational load, suitable for large-scale production without the need for triangulation or complex image processing.
Implementation Method 1
A method using a laser profilometer to scan the capsule and vial profiles
Implementation Method 2
The optical fibres of the receiving head are arranged in a rectangular shape... The optic heads are connected to an optical sensor... As a package having a closure travels down the transport mechanism, the package closure interrupts portions of the light beam directed at the receiving head
Data Source
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AI summary
Method for detecting defects in the closure of encapsulated vials, comprising the following steps: a) Scanning a profile of the capsule and of the vial using a profilometer, thus obtaining a point cloud. b) From the point cloud obtained in the previous step, calculating at least one of the following parameters: i. Diameter or radius of the closure circumference of the capsule. ii. Angle of intersection between the lower skirt and the side of the capsule. iii. Length of the lower skirt. iv. Distance from the end of the lower skirt to the neck of the vial. c) Determining whether any of said parameters calculated in the previous step exceeds a predetermined limit value. And device for detecting defects in the closure of encapsulated vials, comprising a profilometer configured to scan a profile of the capsule and of the vial and a control device configured to execute a method such as that described earlier.