Optically Verified Transfer Tray Filling for Drug Portion Accuracy
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Solution Overview
Problem
Automatic blister packaging machines face challenges in accurately filling transport trays with drug portions due to the high likelihood of incorrect filling, especially when dealing with infrequently requested drugs with short expiration dates or unique physical properties, leading to time-consuming corrections and potential errors.
Innovation Solution
A filling station and method that utilizes a transfer tray with optical detection and a control device to generate filling templates, compare actual filling to target filling, and open a closing device only when no deviation is detected, ensuring accurate transfer of drug portions to a transport tray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual filling of transport trays is performed, then flexibility in handling infrequently requested drugs is maintained, but the risk of incorrect filling increases significantly
Solution Approach 1:
The patent replaces manual mechanical filling operations with an automated optical detection and control system. Cameras capture images of the transport tray, and a control device processes these images to verify correct filling, substituting human visual inspection and manual correction with automated optical-mechanical systems.
Solution Approach 2:
The system implements feedback control by capturing images of the filled transport tray, comparing the actual filling state against the prescribed filling plan, and providing visual feedback through a display device. This feedback loop enables real-time verification and correction of filling errors, significantly improving reliability.
2Manufacturing precision
If optical detection and verification systems are implemented, then filling accuracy is significantly improved, but the device complexity and initial setup requirements increase
Solution Approach 1:
The patent introduces an intermediary optical detection system that acts as a mediator between the manual filling process and the verification process. Cameras and image processing systems serve as intermediaries to capture and analyze the filling state without directly interfering with the manual filling operation, thereby improving precision while maintaining operational simplicity.
3Measurement precision
If closing device is kept open for inspection, then filling verification can be performed, but the risk of drug portion loss or contamination increases
Solution Approach 1:
The system performs preliminary visual verification using optical detection before the closing device is opened. By capturing and analyzing images while the tray is still closed and protected, the system verifies filling accuracy without exposing the drug portions to contamination risks associated with opening the closing device.
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 significantly reduces the probability of incorrect filling by visually verifying and correcting the filling process, ensuring the transport tray meets the target filling requirements before transferring drug portions to the machine tray, thereby enhancing accuracy and efficiency.
Implementation Method 1
an optical detection device configured to generate one or more images of filling receptacles having drug portions arranged therein
Data Source
AI summary
Filling stations are provided that include a transfer tray having filling receptacles and a closing device arranged under the filling receptacles to open and close bottom openings in the filling receptacles, an optical detection device to generate images of filling receptacles having drug portions arranged therein, and a control device coupled to the optical detection device. The control device causes displaying of a filling template of which filling receptacles are to be filled with one or more drug portions, comparing an actual filling of the filling receptacles based on the one or more images of the filling receptacles generated by the optical detection device to a target filling, determining that no deviation exists between the actual filling and the target filling, and opening the closing device for transferring the drug portions from the transfer tray to a transport tray. Systems and methods for filling a transfer tray are also provided.