Optical Capsule Filling Control via Light Transmission Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current capsule filling machines lack efficient quality control methods for monitoring the filling of medicaments, particularly for small fill quantities, as existing methods are either laborious, inaccurate, or disrupt the high-throughput production process, and do not provide 100% monitoring of capsules.
Innovation Solution
The process involves detecting and regulating the optical characteristics of capsule carriers to ensure consistent image quality during image analysis, allowing for quantitative evaluation of the filling by adjusting the optical system and using a computer program to monitor and regulate the filling process, enabling continuous, high-speed monitoring of capsules without slowing down production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If random sampling and weighing is used for quality control, then filling accuracy can be assessed, but the process is laborious and cannot provide 100% monitoring
Solution Approach 1:
The patent replaces the mechanical weighing system with an optical measurement system. Light beams are transmitted through the capsule carriers, and the intensity distribution of the transmitted light is analyzed to determine fill quantity. This substitution enables non-contact, high-speed optical measurement that can keep pace with high-throughput filling operations while providing precise filling assessment.
Solution Approach 2:
The patent creates an optical copy or representation of the fill quantity through light transmission patterns. Instead of physically weighing each capsule, the system captures optical information (light intensity distribution) that corresponds to the fill amount, enabling rapid assessment without handling or weighing each individual capsule.
2Ease of operation
If light beam transmission through capsules is used for filling control, then qualitative filling assessment is possible, but precision is inadequate for small fill quantities
Solution Approach 1:
The patent applies local quality by using multiple light beams at different positions and/or wavelengths, and by analyzing the local intensity distribution pattern across the transmitted light. Different regions of the light transmission provide information about different aspects of the fill, enabling precise quantitative measurement even for small fill quantities through localized optical property analysis.
3Reliability
If 100% monitoring of capsules is implemented, then quality control is improved, but the filling process may be slowed down
Solution Approach 1:
The patent implements continuous optical monitoring that operates simultaneously with the filling process. The light transmission measurement is a non-contact, instantaneous process that does not interrupt the capsule filling operation, allowing 100% quality monitoring to be achieved without reducing throughput. The optical measurement continues continuously as capsules are filled and transported.
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
This solution allows for precise, quantitative monitoring of capsule filling, ensuring accurate evaluation of fill quantities and maintaining high production throughput by adjusting light intensity and image processing to account for variations in capsule carriers, resulting in effective quality control with minimal delay.
Implementation Method 1
The quality of the capsules is assessed on the basis of the random samples and corresponding statistical evaluation. Generally, the random sampling is done by weighing.
Implementation Method 2
two light beams are shone through the capsules. The filling in the capsules interrupts the light beams. Therefore, using the intensity distribution in the beam transmitted, conclusions can be drawn as to the level of filling of the capsules with powder.
Data Source
AI summary
The present invention relates to a method for monitoring the filling of a capsule with a medicament, to a corresponding filling method, to the associated apparatuses, and to a computer program for controlling the method and the apparatus. In the monitoring method, after at least part of the capsule has been filled with a predefined filling mass of a predefined closed contour of the medicament, at least the filling mass in the part of the capsule after the filling operation is recorded using digital imaging in a first step, the contour of the filling mass in the part of the capsule is determined from the digital imaging recording in a second step, and the contour is analysed in a third step in order to assess the filling operation in comparison with the predefined contour. The invention provides for external influences on the image properties to be compensated for by controlling the optical system.