Sealed Contact Lens Package Inspection for Post-Sealing Defects
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Solution Overview
Problem
Existing quality control systems for sealed contact lens packages are inadequate in detecting foreign matter, missing lenses, or multiple lenses after the sealing process, as they do not account for potential contamination or mispackaging that may occur post-inspection.
Innovation Solution
A system comprising an end effector, light box with internal reflective surface, and sensors to capture spectral data and analyze images using machine learning and rule-based algorithms to identify defects such as foreign matter, missing lenses, or multiple lenses in sealed packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If quality control inspection is performed prior to sealing, then inspection efficiency is improved, but detection accuracy deteriorates due to post-inspection contamination or lens loss
Solution Approach 1:
The system performs quality control inspection after sealing by using image capture devices to photograph the sealed package contents, allowing detection of foreign matter, missing lenses, or multiple lenses that may have been introduced during the sealing process
Solution Approach 2:
The system uses image analysis with machine learning models to automatically detect defects and provide feedback for package rejection, creating a closed-loop quality control system that continuously monitors and improves detection accuracy
2Device complexity
If traditional inspection methods are used, then device complexity is reduced, but quality control reliability deteriorates due to inability to detect post-sealing defects
Solution Approach 1:
The system replaces manual inspection methods with automated image capture and machine learning-based analysis, substituting mechanical inspection processes with optical and computational systems that can reliably detect post-sealing defects
Solution Approach 2:
The system introduces an intermediary image capture device and analysis system between the sealing process and final product release, acting as a mediator that verifies package contents without requiring direct physical handling of the sealed packages
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
Effectively detects and segregates packages with defects, ensuring high accuracy in identifying and rejecting packages with anomalies, thereby maintaining product quality and reducing downstream contamination risks.
Implementation Method 1
a light source disposed to emit light into the light cavity
Implementation Method 2
a housing having an internal curved reflective surface defining at least a portion of a light cavity
Data Source
AI summary
A method for quality control of sealed contact lens packages may comprise disposing a package of a sealed contact lens in a light box, causing the package to be illuminated in the light box by a light source, capturing image data of the illuminated package in the light box, analyzing, based on one or more quality control models, the image data of the illuminated package in the light box, and causing, based on the analyzing, output of a quality control metric indicative of at least an accept or reject condition of the package.