Optical Syringe Plunger Depth Inspection for Faster QC
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Solution Overview
Problem
Current syringe quality control processes for pre-filled syringes rely on manual measurement of plunger depth using calipers, which is inefficient and prone to errors, leading to failed quality control if the plunger depth does not match the unique requirements for each drug product.
Innovation Solution
An automated syringe measurement system utilizing a camera and imaging system to measure plunger depth accurately and simultaneously, with a processor determining whether the depth is within a predetermined tolerance, and integrating a syringe carrying tub assembly, syringe removal tool, and syringe rack for efficient handling and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement using calipers is used, then measurement can be performed, but measurement precision and productivity are insufficient
Solution Approach 1:
The patent replaces the manual mechanical measurement system (calipers) with an automated optical imaging system consisting of a camera, illumination source, and processor. The imaging system captures images of multiple syringes simultaneously, and the processor automatically determines plunger depth by analyzing the images, eliminating the need for manual mechanical measurement and significantly improving both precision and productivity
Solution Approach 2:
The patent combines multiple measurement functions into a single integrated system. The imaging system captures images of multiple syringes at once, and the processor performs multiple measurements (plunger depth, bubble presence, liquid level) simultaneously from the same images, increasing productivity while maintaining precision
2Reliability
If manual measurement is used, then measurement can be performed, but time consumption is excessive
Solution Approach 1:
The automated optical system with image processing replaces time-consuming manual measurement operations. The processor can analyze multiple syringes in parallel from captured images, determining plunger depth and other parameters automatically without sequential manual intervention, dramatically reducing time per measurement while ensuring consistent quality control
Solution Approach 2:
The imaging system captures all necessary measurement data in a single image capture step before any analysis occurs. The processor then extracts multiple parameters (plunger depth, bubble detection, liquid level) from the pre-captured images, eliminating the need for multiple sequential measurement actions and reducing total measurement time
3Productivity
If automated imaging system is used, then measurement precision and productivity improve, but device complexity increases
Solution Approach 1:
The imaging system is designed to perform multiple quality control functions using the same core components. The camera and illumination system capture images that the processor analyzes for various parameters including plunger depth, bubble presence, and liquid level, allowing one system to replace multiple specialized devices and reducing overall complexity
Solution Approach 2:
The system uses optical imaging to create digital copies of the syringes and their contents. These image copies are then processed computationally to extract measurement data, replacing the need for direct physical interaction with each syringe and simplifying the measurement process while 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
The automated system provides precise, accurate, and rapid measurement of multiple syringes, reducing human error, increasing throughput, and requiring fewer personnel, while securely recording quality data and batch numbers.
Implementation Method 1
an imaging system capable of generating imaging data. The imaging system may include a camera
Implementation Method 2
a camera, an imaging surface, and an illumination source
Implementation Method 3
an illumination source
Data Source
AI summary
Automatic syringe quality control systems, apparatus and methods are provided. The automatic syringe quality control systems, apparatus and methods may determine a plunger depth within a syringe that has been pre-filled with a medication. The plunger depth may be based on digital image data.