Automated Optical Inspection of Plastic Culture Carriers
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Solution Overview
Problem
Current methods for inspecting plate-like plastic carriers, such as Petri dishes, are labor-intensive, prone to human error, and costly due to manual examination and documentation, especially in industries like food, pharmaceuticals, and medical, where consistency and accuracy in germ detection are critical.
Innovation Solution
An automated inspection method using a computer-controlled handling unit with an optical inspection system that reads unique identification codes, evaluates images of the culture medium for germ growth and faults, and documents results, reducing user intervention and increasing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual examination by trained personnel is used, then flexibility in handling various inspection cases is maintained, but the examination becomes extremely time-consuming and cost-intensive with varied and error-prone results
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated optical inspection system using cameras and image processing algorithms. The system captures images of the culture medium and automatically analyzes them for germ growth, eliminating human variability and significantly increasing inspection throughput while maintaining or improving result consistency.
Solution Approach 2:
The inspection system performs self-evaluation through automated image analysis. The computer-controlled system independently processes images, detects germ growth patterns, and generates inspection results without requiring continuous human intervention, thereby achieving both high reliability and productivity.
2Loss of time
If manual documentation of inspection results is performed, then flexibility in recording various findings is possible, but the documentation process becomes time-consuming and cost-intensive
Solution Approach 1:
The patent replaces manual documentation with automated digital documentation. The optical inspection system captures images that are automatically processed and stored in digital format, eliminating the need for manual writing or data entry. This significantly reduces documentation time while the digital storage and processing infrastructure manages the complexity.
Solution Approach 2:
The system creates digital copies of the inspection results through image capture and data storage. Instead of manual recording, the actual visual evidence is copied and stored digitally, making documentation instantaneous and eliminating transcription errors while reducing time loss.
3Measurement precision
If identification codes are read after removing plastic carriers from storage container, then accurate identification is achieved, but the cycle time between removals increases
Solution Approach 1:
The patent performs the identification code reading operation in advance, before the plastic carrier is fully removed from the storage container. The reading unit detects codes while carriers are still in position, allowing the system to prepare identification data beforehand and reduce the cycle time between sequential operations without compromising identification accuracy.
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 method enables consistent, high-quality inspection of multiple plastic carriers with reduced error rates and increased efficiency, allowing for precise detection of germs and faults, and simplifies further inspections by automating the processing of results.
Implementation Method 1
a reading unit is provided, in that the reading unit is configured to read the identification code of the plastic carrier
Implementation Method 2
an optical inspection system is provided, in that at least one image of the plastic carrier, including the surface of the culture medium, is recorded with the aid of the inspection system
Data Source
AI summary
A method for an automatic inspection of a plurality of plate-like plastic carriers, whereby each plastic carrier is closed by a cover and has a unique identification code and a culture medium. A storage container including a multiplicity of plastic carriers is provided, and a computer-controlled handling unit including an optical inspection system is provided. While performing the automatic inspection in an inspection routine, a plastic carrier is removed from the storage container with the aid of the handling unit, the cover of the plastic carrier is subsequently removed, the plastic carrier is supplied to the inspection system, the identification code is read, and at least one image of the plastic carrier, including the surface of the culture solution is recorded. The image is evaluated for a growth of germs and/or faults in the plastic carrier and the result of the evaluation is stored for each plastic carrier.