can play a key role in effective and responsive inspection of blister packs .
The power of vision system-based inspections
Vision systems typically combine cameras , sensors , lighting and advanced software to capture and analyse images of blister packs as they move through production lines . More precisely , the process begins with high-resolution cameras and lights strategically positioned to generate and capture detailed images . The number and their placement depend on the complexity of the inspection required and the specific setup . For example , various lighting techniques can be used . These include diffuse , direct and backlighting , to eliminate shadows , reflections or other image distortions .
State-of-the-art vision systems can advance quality control activities , improving speed , accuracy and end results ( Image source : iStock : 1607466465 )
Once the images are captured , they are processed by powerful algorithms . These are designed to detect and analyse specific features , irregularities , defects and other attributes of the blister packs - and the tablets within - that could compromise product quality or safety . The software compares the images against predefined criteria to determine whether each pack meets the required quality standards .
Blister packs that pass the inspection are allowed to move to any downstream operation , while those that have been flagged are automatically diverted and rejected from the line . This ensures that only compliant packs make their way to the next stages .
Vision systems can also provide detailed data and documentation of the inspection process , including images of inspected blister packs , timestamps and records of any defects detected . This information can support comprehensive reporting and quality auditing activities to ensure regulatory compliance . Even more , they support traceability strategies .
The future ahead
With the capabilities of artificial intelligence ( AI ) evolving considerably , vision systems are deemed to become even more complex , accurate and smarter . For example , they can integrate increasingly advanced spectral functions , sensors , pattern recognition algorithms and data processing functions . Thanks to these , they can detect subtle anomalies that may not otherwise be identifiable .
Even more , thanks to the latest progress in unsupervised machine learning and deep learning , creating accurate vision systems is becoming quicker . This ultimately streamlines key project and helps end users benefit from quick returns on investment ( ROI ). Additionally , the development of innovative 3D vision technology will allow vision systems to provide even more detailed and accurate quality control , particularly for complex blister pack designs .
Case study : integrating advanced inspection machines in existing facilities
When a tablet manufacturer was surprised by the sudden breakdown of its three blister pack inspection machines , it was necessary to manually scrutinise products as a temporary yet highly expensive
solution . To overcome this issue and restart automated operations , the company contacted Optimal Industrial Automation , which could provide responsive , localised support and deliver a robust , futureoriented setup .
The new inspection machines developed by the industrial automation specialist consist of two vision systems monitoring the products as the move on a conveyor . The first component identifies a faulty item and tracks it , while the second , located at the end of the line , rejects any unsuitable pack .
The three identical solutions look for colour , shape and dimensions , as well as absence of OSD forms . They are also highly versatile , as they can be used by the manufacturer to monitor different medicaments .
Finally , the setups were seamlessly integrated with existing assets on the shop floor . In particular , to support the advanced functions of the new machines as well as the needs of the remaining equipment , Optimal replaced the controller with a more powerful PLC . This can handle data-intense operations while offering a scalable framework that enables future upgrades .
For further information , please visit www . optimal-ltd . co . uk
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