Vision System for Fluid Volume Calculation in Syringes
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Solution Overview
Problem
Existing methods for determining the volume of fluid in containers, particularly in automated medication preparation systems, are cumbersome, prone to error, and not suited for precision, especially when dealing with syringes, as they often involve manual observation or transfer, which can lead to evaporation or contamination issues.
Innovation Solution
A vision system utilizing an imaging device to capture images of the fluid in a container against a background with contrasting colors, processing the images to calculate the volume by analyzing the air-liquid interface and plunger position, allowing for precise measurement and integrity checking of the syringe fill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual observation and graduation system are used to calculate fluid volume, then the method is simple to implement, but it is cumbersome and time-consuming with high error rate
Solution Approach 1:
The patent replaces manual mechanical observation and graduation reading with an automated vision system using imaging devices and image processing algorithms. The system captures images of the fluid in the container and automatically calculates volume through computational analysis, eliminating manual intervention and significantly improving both speed and accuracy.
Solution Approach 2:
The patent creates a digital copy (image) of the fluid container and analyzes this copy to determine volume. Instead of physically measuring the fluid, the system captures visual information and processes it to calculate volume, enabling rapid and repeatable measurements without physical contact with the fluid.
2Measurement precision
If manual transfer to measurement device is used, then volume can be measured, but liquid may evaporate or be left behind reducing precision
Solution Approach 1:
The system creates a digital image copy of the fluid in its original container and analyzes this copy to determine volume. This eliminates the need to physically transfer the liquid to a measurement device, preventing evaporation and residue losses while maintaining measurement precision.
Solution Approach 2:
The patent replaces the mechanical process of liquid transfer with an optical measurement system. By using imaging devices to capture and analyze the fluid's visual characteristics (such as meniscus position and fluid level), the system determines volume without physical contact, thereby preventing liquid loss.
3Productivity
If automated vision system is implemented, then measurement precision and productivity are improved, but device complexity increases
Solution Approach 1:
The vision system is designed to handle multiple container types and fluid conditions through a single unified platform. The imaging device and processing algorithms can adapt to different container geometries, fluid viscosities, and lighting conditions, providing universal applicability that justifies the initial system complexity through broad functionality.
Solution Approach 2:
By using digital imaging and computational analysis, the system achieves high measurement precision and speed without requiring complex mechanical measurement apparatus. The optical system combined with software algorithms provides a relatively simple hardware architecture compared to traditional mechanical measurement devices, while delivering superior performance.
4Manufacturing precision
If 100% inspection of filled syringes is performed, then manufacturing precision and reliability are improved, but inspection time increases
Solution Approach 1:
The patent replaces slow manual inspection with automated optical measurement and image processing. The vision system rapidly captures and analyzes images of filled syringes, providing 100% inspection coverage at high speed. The computational algorithms automatically determine fill volume and detect anomalies, enabling thorough inspection without time penalty.
Solution Approach 2:
The vision system enables continuous inspection of all syringes as they pass through the measurement station. Rather than intermittent sampling, the system provides continuous 100% inspection capability, maintaining manufacturing precision while improving overall throughput through rapid automated analysis.
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 an efficient and accurate method for calculating the volume of fluid in containers, reducing human error and ensuring precise filling in automated systems, enhancing the reliability and efficiency of medication preparation by enabling 100% inspection of filled syringes before further processing.
Implementation Method 1
an imaging device that captures and stores an image of at least the volume of fluid in the container
Data Source
AI summary
Broadly speaking the present invention is directed to a system for calculating a volume of fluid that is disposed within a container. The system includes (1) an imaging device that captures and stores an image of at least the volume of fluid in the container; (2) a background disposed behind the container so that at least the volume of fluid in the container is disposed in front of the background; and (3) a processor that performs at least one operation on the stored image to calculate the volume of the fluid within the container.