Mimic AVI Station Replication for Offline Troubleshooting
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Solution Overview
Problem
Existing automated visual inspection (AVI) systems for pharmaceutical products are large, complex, and costly, requiring lengthy downtimes for troubleshooting and new product characterization, which disrupts production and is inefficient.
Innovation Solution
A mimic AVI station is constructed or upgraded to replicate the performance of existing AVI stations, allowing offline troubleshooting and characterization, using techniques such as reverse engineering, 3D scanning, and image comparison tools to ensure accurate replication of hardware and software components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If troubleshooting and characterization are performed on the existing AVI station, then problem resolution and product qualification can be achieved, but production downtime increases significantly
Solution Approach 1:
The patent creates a mimic AVI station that replicates the functionality and inspection capabilities of the existing AVI station. This copy allows all troubleshooting and characterization activities to be performed on the mimic station without affecting production on the original station, thereby eliminating production downtime while maintaining full troubleshooting effectiveness
Solution Approach 2:
The mimic AVI station is set up and configured in advance before any troubleshooting or characterization is needed. This preliminary action allows the station to be ready for immediate use, enabling offline work to be performed without interrupting production schedules
2Ease of operation
If a mimic AVI station is constructed to replicate existing station performance, then offline troubleshooting capability is enabled, but device complexity and initial setup time increase
Solution Approach 1:
Rather than building a completely new complex system, the patent replicates the existing AVI station's configuration, hardware, and software. This copying approach leverages the already-validated design, reducing the need for additional complexity while achieving the desired offline troubleshooting capability
Solution Approach 2:
The mimic AVI station is designed to perform multiple functions: it serves as both a production inspection station and an offline troubleshooting platform. This multi-functionality reduces the need for separate dedicated troubleshooting equipment, thereby reducing overall device complexity
Data Source
AI summary
In a method for replicating performance of an automated visual inspection (AVI) station, a mimic AVI station that performs one or more AVI functions of the AVI station is constructed. One or more container images are captured by an imaging system of the AVI station while a container is illuminated by an illumination system of the AVI station, and one or more additional container images are captured by a mimic imaging system of the mimic AVI station. The method also includes identifying, by one or more processors, one or more differences between the one or more additional container images and the one or more container images, generating, by the one or more processors, a visual indication of the difference(s) and/or one or more suggestions for modifying the mimic AVI station, and modifying the mimic AVI station based on the visual indication.