360° Optical Runout Measurement for Molded Drug Device Components
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Solution Overview
Problem
Existing systems for measuring circular runout or concentricity in molded medical device components, such as syringe stoppers and plungers, provide inaccurate and variable data, leading to potential misalignment and functional issues in drug delivery devices, and are often time-consuming to operate.
Innovation Solution
A method and system utilizing a light source and optical imaging sensor to capture 2D images of the component as it rotates, determining the position of outer edge points and comparing their positions to measure circular runout, concentricity, and cylindricity, with a controller analyzing the data to assess mold alignment and condition for improved quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing measurement systems are used to measure circular runout or concentricity, then measurement capability is provided, but measurement accuracy and reliability deteriorate due to high variability in the data
Solution Approach 1:
The patent replaces mechanical contact-based measurement systems with an optical measurement system. The optical system uses a light source and optical sensor to capture images of the component as it rotates, eliminating mechanical contact that introduces variability. The controller processes these optical images to determine outer edge points and calculate circular runout, providing more accurate and reliable measurements without physical interference.
Solution Approach 2:
The patent creates an optical copy (image) of the component's geometry rather than measuring it mechanically. The optical sensor captures a visual representation of the component's outer surface, and the controller analyzes this optical copy to determine precise edge points and calculate runout. This copying approach preserves the original component while obtaining highly accurate measurement data.
2Measurement precision
If existing measurement systems are used, then measurement capability is provided, but measurement time increases making the process time-consuming
Solution Approach 1:
The patent implements continuous measurement during component rotation. As the component rotates on the presentation stage, the optical sensor continuously captures images at multiple angular positions. The controller processes these images in real-time to track outer edge points throughout the rotation, enabling complete circular runout measurement in a single continuous operation rather than through multiple discrete measurements.
Solution Approach 2:
The patent uses periodic image capture synchronized with the component's rotation. The optical sensor captures images at regular angular intervals as the component rotates, and the controller processes these periodically captured images to determine outer edge points at each position. This periodic sampling approach efficiently captures all necessary measurement data during one rotation cycle.
3Ease of operation
If manual measurement methods are used, then measurement can be performed, but operator variability introduces errors reducing consistency
Solution Approach 1:
The patent implements an automated measurement system that performs all measurement tasks without human intervention. The optical sensor automatically captures images, the controller automatically processes these images to identify outer edge points, and the system automatically calculates circular runout values. This self-service approach eliminates operator variability entirely, providing consistent and repeatable measurements across different operators and time periods.
Solution Approach 2:
The patent incorporates automated feedback processing where the controller continuously analyzes optical images to determine outer edge points and calculate runout values. The system provides immediate feedback on measurement results and can compare measurements against specifications, eliminating the subjectivity and variability inherent in manual measurement and judgment.
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
The system provides more accurate and reliable measurements of molded part parameters, reducing operator variability and enabling timely mold maintenance decisions, thus enhancing the quality and reliability of high-volume part manufacturing.
Implementation Method 1
providing a light source in an opposing relationship with an optical imaging sensor, wherein the light source and the optical imaging sensor are arranged such that light emitted from the light source impinges upon at least a portion of the optical imaging sensor
Data Source
Figure 1
Figure 2A~2B
Figure 3~3(f)
AI summary
Methods and systems for measuring a component of a drug delivery or storage device are described. The method comprises providing a light source in an opposing relationship with an optical imaging sensor; positioning a sample component on a positioning stage located between the at least one light source and at least one opposing optical imaging sensor; and illuminating, with the at least one light source, the sample component. The controller is operable to capture an image of the component, determine the location of a first outer edge point PI of the captured image; rotate the sample component relative to the optical image sensor, and collect n images separated from each other by x degrees of rotation, wherein n*x is ≥ 360 degrees. The controller may compare a measured position of the at least one outer edge point PI between the captured images to determine a degree or circular runout.