Optical Inspection for Free-Falling Items Dispensing
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Solution Overview
Problem
Existing dispensing systems face challenges in accurately and efficiently dispensing discrete items into batches while ensuring the items meet specific quality criteria, particularly in the pharmaceutical industry where strict regulations demand high accuracy and prevention of cross-contamination.
Innovation Solution
The method involves allowing items to free-fall into a collection volume, using a digital imaging device to capture images of the falling items, and processing these images to count the items and determine their characteristics, such as color, in real-time, allowing for precise dispensing and quality inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical counting mechanisms are used to ensure accurate dispensing, then manufacturing precision is improved, but productivity decreases due to slow processing speeds
Solution Approach 1:
The patent replaces mechanical counting mechanisms with an optical imaging system. A digital imaging device captures images of items as they pass through a field of view, and image processing algorithms automatically count and inspect the items. This substitution eliminates the mechanical contact and slow processing of traditional counters while enabling high-speed optical inspection and counting, thus improving both productivity and maintaining dispensing accuracy.
2Productivity
If high-speed dispensing is implemented to improve productivity, then processing speed increases, but manufacturing precision deteriorates due to reduced inspection accuracy
Solution Approach 1:
The patent creates an optical copy (image) of the items as they pass through the dispensing system. The digital imaging device captures a visual representation of each item, and image processing algorithms analyze this copy to determine item characteristics and count the items. This copying approach allows high-speed inspection because the analysis is performed on digital images rather than through slow mechanical measurement, maintaining both high productivity and inspection accuracy.
3Reliability
If multiple inspection criteria are applied to ensure quality, then reliability improves, but device complexity increases due to additional inspection systems
Solution Approach 1:
The patent implements a multi-functional imaging system where a single digital imaging device performs multiple inspection functions simultaneously. The same optical system and image processing algorithms are used for counting items, inspecting their characteristics, and verifying quality criteria. This universal approach eliminates the need for separate inspection devices for each function, reducing system complexity while maintaining high reliability through comprehensive quality checking.
4Measurement precision
If manual inspection methods are used to verify item quality, then measurement precision is improved, but productivity decreases due to slow manual processing
Solution Approach 1:
The patent replaces manual inspection with an automated optical measurement system. The digital imaging device captures high-resolution images of the items, and computer vision algorithms automatically measure and evaluate item characteristics such as size, shape, color, and defects. This automated optical measurement provides both the precision needed for quality verification and the high speed required for productive operation, eliminating the trade-off between manual accuracy and automated speed.
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 approach enables rapid and accurate dispensing of items into batches of predetermined sizes, while ensuring that only items meeting specific quality criteria are included, thereby improving efficiency, reducing errors, and adhering to strict industry regulations.
Implementation Method 1
employing a digital imaging device to acquire images of the items while said items are falling
Data Source
AI summary
There is provided a method and apparatus for counting items and identifying rogue or deviant items, for example in bulk of falling items.