Pharmaceutical Item Packaging with Camera-Based Label Verification
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Solution Overview
Problem
Existing packaging systems for pharmaceutical items lack efficient verification and packaging processes, particularly in prescription fulfillment operations, leading to potential errors in labeling and packaging accuracy.
Innovation Solution
An item packaging machine (IPM assembly) with a conveyor system, labeling verification cameras, and packaging verification cameras that ensure accurate application of customer and order information by comparing captured images with database information, and a modular assembly for flexible operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual verification and packaging processes are used, then operational flexibility is maintained, but labeling accuracy and packaging precision deteriorate due to human error
Solution Approach 1:
The patent replaces manual verification and labeling operations with an automated system comprising verification cameras, processing systems, and label applicators. The verification cameras capture images of items, the processing system compares captured images with database information to verify accuracy, and the label applicator automatically applies labels. This substitution of mechanical/manual operations with automated optical and computational systems resolves the contradiction by improving labeling accuracy while managing system complexity through integration.
Solution Approach 2:
The system performs self-verification by automatically capturing images, comparing them with database information, and determining whether items are correctly identified and labeled without requiring manual intervention. The processing system autonomously makes decisions about label application based on verification results, enabling the system to serve itself and eliminate human error in the verification process.
2Manufacturing precision
If automated verification systems are implemented, then labeling accuracy improves, but processing time increases due to additional verification steps
Solution Approach 1:
The system performs verification actions in advance by capturing images of items and comparing them with database information before the actual labeling process. This preliminary verification ensures that items are correctly identified and prevents errors downstream, resolving the contradiction by establishing accuracy early in the process while maintaining efficient workflow through pre-validation.
Solution Approach 2:
The verification cameras and processing system operate continuously alongside the conveyor belt, performing verification tasks without interrupting the flow of items. The system maintains continuous operation by processing verification data in real-time and seamlessly transitioning to label application, thereby improving packaging accuracy without significant time loss.
3Measurement precision
If multiple verification cameras are positioned throughout the conveyor run, then detection precision improves, but device complexity increases
Solution Approach 1:
The verification system is segmented into multiple discrete camera stations positioned at different locations along the conveyor run. Each camera is responsible for capturing images at specific verification points, allowing the system to achieve high detection precision through distributed verification. This segmentation resolves the contradiction by dividing the verification function into manageable modules that can be independently positioned and maintained.
Solution Approach 2:
The verification cameras serve multiple functions: capturing item images, verifying item identification, confirming label application accuracy, and providing data for the processing system. This multi-functionality allows a single camera system to perform multiple verification tasks, improving detection precision without proportionally increasing device complexity.
Data Source
AI summary
An item packaging machine is configured to fulfill a plurality of orders that each include one or more items. The item packaging machine includes an introduction assembly configured to index each item in a retaining notch that is advanced by a conveyor over a base. The conveyor advances each item to a label applicator assembly, where each item is verified by one or more cameras directed to at least one side of each item and a label is applied to each item. The conveyor advances each labeled item to a packaging assembly, where each item is verified and advanced into a package that includes order identification information applied thereon and that is configured to package the order that includes the item.