Prefilled Syringe Plunger Depth Imaging Without Tray Artifacts
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Solution Overview
Problem
Existing digital image-based syringe inspection systems face challenges in accurately determining plunger depth due to tray-induced optical artifacts, which lead to erroneous measurements in prefilled syringes.
Innovation Solution
A system and method that utilize a digital image data acquisition device with a backlight and image sensor to capture silhouette images of syringe flanges and plungers, while using an intermediate holder to minimize tray-induced optical artifacts, and employ edge detection parameters to accurately determine plunger depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a tray is used to hold prefilled syringes during inspection, then the syringes can be organized and processed in batches, but the tray material creates optical artifacts that interfere with image-based plunger depth measurement
Solution Approach 1:
The patent introduces an intermediate optically clear holder as a mediator between the tray and the imaging system. This holder allows light to pass through without creating artifacts, enabling accurate plunger depth measurement while maintaining batch processing capability. The clear holder acts as an optical intermediary that eliminates the interference caused by the opaque tray material.
2Measurement precision
If backlight intensity is increased to improve image quality, then plunger depth measurement accuracy improves, but energy consumption increases
Solution Approach 1:
The optically clear holder serves as an intermediary that improves light transmission efficiency. By removing the opaque tray material from the optical path, the system achieves better image quality with lower backlight intensity, reducing energy consumption while maintaining measurement precision.
3Measurement precision
If manual inspection methods are used to avoid tray artifacts, then measurement accuracy is maintained, but inspection speed and productivity decrease
Solution Approach 1:
The patent replaces manual inspection with an automated imaging system that uses an optically clear holder. This substitution eliminates the need for manual handling while maintaining measurement accuracy through digital image analysis, thereby increasing inspection speed and productivity.
4Strength
If opaque tray material is used for packaging, then mechanical strength and protection are improved, but optical transparency for inspection is lost
Solution Approach 1:
The system is segmented into two functional parts: an opaque tray for mechanical support and protection, and a separate optically clear holder for inspection. This segmentation allows each component to optimize its primary function - the tray provides strength while the clear holder enables light transmission for accurate imaging.
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 provides precise and accurate plunger depth measurements, reduces the need for manual inspection, and increases inspection efficiency by processing more syringes per minute with fewer personnel, while ensuring product safety and quality control.
Implementation Method 1
The digital image data acquisition device may include an image sensor and a backlight. The digital image data acquisition device may be configured to cause the backlight to emit light having a predetermined intensity.
Implementation Method 2
The image data may be representative of a silhouette of at least the portion of the tubular vessel and at least the portion of the plunger within the tubular vessel.
Data Source
AI summary
Automatic prefilled syringe inspection systems, apparatus and methods are provided. The automatic syringe inspection 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 that is representative of a silhouette of at least a portion of a tubular vessel and at least a portion of a plunger within the tubular vessel.