The present invention relates to automated inspection systems, and in particular pertains to a method as well as a corresponding apparatus for monitoring a drive mechanism of an automated inspection system for inducing motion to a container partially filled with a liquid.
Automated inspection machines are typically employing after filling containers with liquids in order to check the fill level, verify that the containers are correctly sealed, i.e. not leaking, and to examine whether the content of the container has been contaminated with impurities, which are often manifested as solid particles within the liquid. Furthermore, it is commonly checked whether the containers have defects such as scratches, cracks, deformations, etc. Common liquid containers are bottles and cans, e.g. for beverages, cosmetics or chemicals, as well as vials, ampoules, carpules and syringes for pharmaceutical/medical products. As part of the inspection process the containers are typically rotated, such that they can for instance be viewed from all sides. Frequently they are also rapidly rotated about their vertical axis in order to whirl up and thus make clearly visible unwanted solid particles present within the liquid. Moreover, it is often necessary to rotate containers in order to mix different liquid components contained therein. For this purpose the container to be handled, in particular to be tested, i.e. the unit/device under test, is for instance arranged in a rotation mechanism, e.g. placed on a rotary plate propelled by an electric motor such as a servo drive or stepper motor or clamped between a free-running pressing member and an actuated rotary disc. Alternatively, the containers are agitated in another way than rotating, for instance they may be vibrated, shaken, rattled or swayed, e.g. in order to stir up the liquid within the container.
For correct handling and inspection it must be ensured that the container is actually being rotated, e.g. that the plate/disc is being driven correctly, preferably at the correct speed/rate of rotation. Therefore, it is necessary to verify whether the drive mechanism which is intended to induce motion to the container is operating correctly, i.e. is causing the container to rotate, vibrate, sway from side to side, etc. This is typically achieved by monitoring the drive mechanism itself. For instance, to rotate a container the container is for instance clamped between a driven rotary plate and a pressing member rotatable with the container. Rotation monitoring can be performed by measuring the rotational speed of the rotary plate and comparing the measured rotational speed with a target rotational speed of the rotary plate. This makes it possible to effectively monitor the rotation of the container. However, the required monitoring device can be quite costly and needs extra space to be installed in the inspection machine.
Hence, for certain applications there exists a need for alternative solutions.
It is an object of the present invention to provide alternative means for monitoring a drive mechanism of an automated inspection system for inducing motion to a container partially filled with a liquid, in particular an alternative motion monitoring method as well as an alternative motion monitoring apparatus. This object is achieved by the method according to claim 1 as well as by the apparatus according to claim 9. Specific embodiments of the method and apparatus according to the present invention are given in the dependent claims.
The present invention provides a method for monitoring a drive mechanism of an automated inspection system for inducing motion to a container partially filled with a liquid comprising the steps of:
Hence, the present invention is particularly well suited when automated vision inspection is already being employed for other purposes and the necessary hardware resources, such as an imaging system (either optical, acoustic or x-ray/high energy radiation based), is available and can additionally be used to perform motion detection/monitoring, in particular by merely including a further software module capable of executing this task.
The present invention has the advantage over prior art solutions which monitor the drive mechanism itself, that motion of the liquid inside the container and therewith of the container containing the liquid is detected. In this way it is ensured that the motion intended to be induced by the drive mechanism to the container and/or to the liquid inside the container is truly effective, i.e. that the container and/or the liquid is really in motion.
In an embodiment of the method capturing measurement data, in particular image data, is performed by one of the following means:
In a further embodiment the method further comprises the following step when capturing measurement data, in particular image data, is performed by means of the optical sensor:
In a further embodiment the method comprises the step of applying optical filtering, in particular polarisation or colour filtering.
In a further embodiment the method comprises the step of generating an acoustic/sound signal in a frequency range from 10 Hz to 20 kHz and/or an ultrasound signal in a frequency range from 20 kHz up to 1 MHz in air or up to 25 MHz in the liquid.
In a further embodiment of the method the step of capturing comprises:
In a further embodiment of the method the step of extracting form data comprises at least one of the following:
In a further embodiment of the method the step of detecting comprises at least one of the following:
In a further embodiment of the method the step of capturing and/or the step of extracting comprises applying automated edge detection and/or feature recognition.
In a further embodiment of the method the step of extracting comprises pixel counting, in particular determining a number of pixels within the region of interest having an intensity within a certain predefined (intensity/grey level) interval or above a certain predefined (intensity/grey level) value and comparing the number with a predefined threshold value.
In a further embodiment of the method the step of determining comprises:
In a further embodiment of the method the steps of capturing and extracting are repeated multiple times, in particular at least once, and the step of determining comprises:
As a further aspect of the present invention a method for inspecting a liquid within a container, in particular for identifying (solid) particles present in the liquid, is suggested, comprising inducing motion to the container, for instance rotating, vibrating, shaking, rattling or swaying the container, and further comprising the proposed motion monitoring/detection method according to any one of the embodiments specified above or combinations of these embodiments.
As a further aspect of the present invention a method for mixing a substance and a liquid or for centrifuging a liquid substance in a container is suggested, comprising inducing motion to the container, for instance rotating, vibrating, shaking, rattling or swaying the container, and further comprising the proposed motion monitoring/detection method according to any one of the embodiments specified above or combinations of these embodiments.
Furthermore, the present invention is directed to an apparatus for monitoring a drive mechanism of an automated inspection system for inducing motion to a container partially filled with a liquid, the apparatus comprising:
Motion data regarding the state of motion of the container can then be output by the processor, in particular the image analysis processor.
In an embodiment the apparatus further comprises a motion indicator operationally connected to the processor, in particular the image analysis processor, wherein the motion indicator is adapted to indicate, e.g. display, information regarding the state of motion of the container based on the form data.
In a further embodiment of the apparatus the measuring device, in particular the imaging device, comprises at least one of the following:
In a further embodiment the apparatus comprises a lens, in particular an optical wide-angle lens or a telephoto lens or a zoom lens or a macro lens. Alternatively, an electromagnetic lens, e.g. a magnet or electromagnet arrangement, may be employed, for instance to direct or focus the radiation emitted by an x-ray source.
In a further embodiment the apparatus comprises an optical filter, in particular a polarisation or colour filter.
In a further embodiment of the apparatus the acoustic/sound source is adapted to generate an acoustic/sound signal in a frequency range from 10 Hz to 20 kHz and/or an ultrasound signal in a frequency range from 20 kHz up to 1 MHz in air or up to 25 MHz in the liquid.
In a further embodiment the apparatus comprises a pixel counter, in particular adapted to determine a number of pixels within a region of interest having an intensity within a certain predefined (intensity/grey level) interval or above a certain predefined (intensity/grey level) value. The number can then be compared with a predefined threshold value by means of a comparator.
As a further aspect of the present invention an automated inspection system for inspecting a liquid within a container, in particular for identifying (solid) particles present in the liquid, is suggested, comprising a drive mechanism adapted to induce motion to the container, for instance to rotate, vibrate, shake, rattle or sway the container, and further comprising the proposed motion monitoring/detection apparatus according to any one of the embodiments specified above or combinations of these embodiments.
As a further aspect of the present invention an automated system for mixing a substance and a liquid or for centrifuging a liquid substance in a container is suggested, comprising a drive mechanism adapted to induce motion to the container, for instance to rotate, vibrate, shake, rattle or sway the container, and further comprising the proposed motion monitoring/detection apparatus according to any one of the embodiments specified above or combinations of these embodiments.
It is specifically pointed out that combinations of the embodiments described above can result in even further, more specific embodiments.
The present invention is further explained below by means of non-limiting specific embodiments and with reference to the accompanying drawings, which show the following:
According to the method of the present invention image data of the surface 4 is captured in order to analyse the form of the surface 4 or to extract a specific feature of the surface 4, such as for instance its curvature, based upon which rotation of the container 2 is detected. In the embodiment shown in
The captured image data is then processed by an image analysis processor 11, which for instance performs edge detection and/or feature recognition, and based on the extracted form data regarding the form of the surface 4 detects whether the container 2 is being rotated. The detected rotation data may then be provided to a rotation indicator 14, which for instance sends a signal to a control unit (not shown) connected to the motor 17.
In the examples described above, a rotational motion is induced to the container 2. However, the container 2 can also be arranged/mounted on a plate/disc 16 which agitates the container 2 in some other way, for instance vibrates, shakes, rattles or sways the container 2, e.g. induces a translatory motion, for certain applications.
In an especially simple implementation of the present invention employing a pixel counter the number of pixels within the entire region of interest ROI having an intensity above a certain predefined grey (e.g. darkness) level value are determined with the pixel counter (e.g. counts “dark” pixels). If this number exceeds a predefined threshold the liquid 3 and the container 2 are considered to be in motion. The higher the number determined with the pixel counter the stronger the motion of the liquid 3 and of the container 2. Therefore, the strength of the motion can also be determined from the number of dark pixels determined with the pixel counter. An increase of this number over time would therefore indicate an increase in motion of the liquid 3 and therewith of the container 2, and a decrease of this number over time would indicate a decrease in motion of the liquid 3 and therewith of the container 2.
Number | Date | Country | Kind |
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00737/18 | Jun 2018 | CH | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2019/064746 | 6/6/2019 | WO | 00 |