Detection and characterization of defects in pharmaceutical cylindrical containers
An apparatus for inspecting a pharmaceutical cylindrical container made of glass or of a polymer is provided. A corresponding method for inspecting the pharmaceutical cylindrical container made of glass or of a polymer and to a bundle of pharmaceutical cylindrical containers made of glass or of a polymer is also provided.
1. An apparatus for inspecting a pharmaceutical cylindrical container made of glass or polymer, the apparatus comprising:
a support device configured to support the pharmaceutical cylindrical container and rotate the pharmaceutical cylindrical container around a longitudinal axis;
a light receiving unit comprising a main camera configured to acquire an image of the pharmaceutical cylindrical container;
a light emitting unit comprising, with respect to the main camera, a bright field light source, a radial dark field light source, and an axial dark field light source; and
a control unit configured to control the support device, the light emitting unit, and the light receiving unit to acquire a plurality of images of the pharmaceutical cylindrical container, the plurality of images comprising images taken when only the bright field light source is activated and when only the axial and/or radial dark field light sources are activated.
2. The apparatus of claim 1 , wherein the support device supports the pharmaceutical cylindrical container so that the longitudinal axis and a horizontal axis perpendicular to the longitudinal axis define a horizontal plane, wherein:
the main camera has a centerline that intersects the horizontal plane at an angle in a range selected from a group consisting of 0° or more and 30° or less, 0° or more and 20° or less, and 0° or more and 10° or less, and/or
the bright field light source has a centerline that intersects the horizontal plane at an angle in a range selected from a group consisting of 0° or more and 30° or less, 0° or more and 20° or less, and 0° or more and 10° or less, and/or
the axial dark field light source has a centerline that intersects the horizontal plane at an angle in a range selected from a group consisting of 0° or more and 30° or less, 0° or more and 20° or less, and 0° or more and 20° or less, and/or
the radial dark field light source has a centerline that intersects the horizontal plane at an angle in a range selected from a group consisting of 100 or more and 90° or less, 450 or more and 90° or less, and 700 or more and 90° or less.
3. The apparatus of claim 1 , wherein the support device supports the pharmaceutical cylindrical container so that the longitudinal axis and a vertical axis perpendicular to the longitudinal axis define a vertical plane, wherein:
the main camera has a centerline that intersects the vertical plane at an angle of 60° or more and 90° or less, 70° or more and 90° or less, and 80° or more and 90° or less, and/or
the bright field light source has a centerline that intersects the vertical plane at an angle in a range selected from a group consisting of 60° or more and 90° or less, 70° or more and 90° or less, and 80° or more and 90° or less, and/or
the axial dark field light source has a centerline that intersects the vertical plane at an angle in a range selected from a group consisting of 0° or more and 30° or less, 0° or more and 20° or less, and 0° or more and 20° or less, and/or
the radial dark field light source has a centerline that intersects the vertical plane at an angle in a range selected from a group consisting of 0° or more and 70° or less, 0° or more and 45° or less, and 0° or more and 20° or less.
4. The apparatus of claim 1 , wherein the support device supports the pharmaceutical cylindrical container so that a horizontal axis perpendicular to the longitudinal axis and a vertical axis perpendicular to the longitudinal axis intersect a middle of a cylindrical part of the pharmaceutical cylindrical container at a transversal plane, wherein:
the main camera has a centerline that intersects the transversal plane at an angle in a range selected from a group consisting of 0° or more and 30° or less, 0° or more and 20° or less, and 0° or more and 10° or less, and/or
the bright field light source has a centerline that intersects the transversal plane at an angle in a range selected from a group consisting of 0° or more and 30° or less, 0° or more and 20° or less, and 0° or more and 10° or less, and/or
the axial dark field light source has a centerline that intersects the transversal plane at an angle in a range selected from a group consisting of 60° or more and 90° or less, 70° or more and 90° or less, and 80° or more and 90° or less, and/or
the radial dark field light source has a centerline that intersects the transversal plane at an angle in a range selected from a group consisting of 0° or more and 70° or less, 0° or more and 45° or less, and 0° or more and 20° or less.
5. The apparatus of claim 1 , wherein the light receiving unit further comprises a plurality of cameras.
6. The apparatus of claim 5 , wherein the plurality of the cameras is between 5 to 25 cameras.
7. The apparatus of claim 1 , wherein the light emitting unit comprises a property selected from the group consisting of: the bright field light source having a light emitting plane that has a size in a range a range selected from a group consisting of 20 cm 2 to 2000 cm 2 , 15 cm 2 to 1000 cm 2 , and 25 cm 2 to 600 cm 2 ; the radial dark field light source having a light emitting plane that has a size in a range a range selected from a group consisting of 0.5 cm 2 to 2000 cm 2 , 0.8 cm 2 to 1000 cm 2 , and 1 cm 2 to 400 cm 2 ; the axial dark field light source having a light emitting plane that has a size in a range a range selected from a group consisting of 0.5 cm 2 to 1000 cm 2 , 0.8 cm 2 to 200 cm 2 , and 1.0 cm 2 to 64 cm 2 ; and any combinations thereof.
8. The apparatus of claim 1 , wherein the bright field light source, the radial dark field light source, and the axial dark field light source each comprise a light emitting plane, wherein:
the light emitting planes have a property selected from the group consisting of: a color temperature between 2000 K and 7000 K, a color temperature between 3000 K to 6000 K, a color temperature between 4000 K to 5000 K, and combinations thereof, and/or
the light emitting planes of the axial and the radial dark field light sources each have a luminous flux that are higher than a luminous flux of the light emitting plane of the bright field light source; and/or
the support device has a distance between each of the light emitting planes that is in a range selected from a group consisting of 5 to 50 cm, 8 to 30 cm, 10 to 20 cm, and combinations thereof.
9. The apparatus of claim 1 , wherein the light emitting unit has a first light emitting plane and a second light emitting plane adjoining each other, wherein the first light emitting plane and the second light emitting plane intersect at an angle in a range selected from a group consisting of 10° to 80 °, 30° to 60°, and 40° to 50°.
10. The apparatus of claim 1 , wherein the support device comprises at least two support wheels and a friction wheel arranged such that the pharmaceutical cylindrical container is on the support wheels and is rotatable around the longitudinal axis by the friction wheel.
11. The apparatus of claim 1 , wherein the control unit is further configured to control the support device, the light emitting unit, and the light receiving unit to perform a task selected from a group consisting of: measure the pharmaceutical cylindrical container in 0.3 to 10 seconds; rotate the pharmaceutical cylindrical container 360° around the longitudinal axis; rotate the pharmaceutical cylindrical container in increments between 0.5° and 4°; rotate the pharmaceutical cylindrical container in between the image acquisitions;
activate/deactivate the main camera based on the speed of a friction wheel; and any combinations thereof.
12. The apparatus of claim 1 , wherein the control unit controls to disregard any container having a defect with a property selected from a group consisting of: a size of 200 μm; a size of 100 μm or more; a size of 80 μm or more; a size of 50 μm or more; a size of 40 μm or more; a size of 20 μm or more; a size of 16 μm or more; a metallic defect on a surface of the pharmaceutical cylindrical container; a non-metallic defect on a surface of the pharmaceutical cylindrical container; a bubble within a wall or on a surface of pharmaceutical cylindrical container; a metallic defect within a wall of pharmaceutical cylindrical container; a non-metallic defect within a wall of the pharmaceutical cylindrical container; and any combinations thereof.
13. A method for inspecting a pharmaceutical cylindrical container made of glass or polymer, comprising:
arranging the pharmaceutical cylindrical container with a lateral surface on a support device;
rotating the pharmaceutical cylindrical container around its longitudinal axis; and
activating a light emitting unit and a light receiving unit to acquire a plurality of images of the pharmaceutical cylindrical container,
wherein the plurality of images comprise images when only a bright field light source is activated and when only an axial dark field light source and/or a radial dark field light source is activated.
14. The method of claim 13 , wherein the bright field image, the axial dark field image, the radial dark field image and/or the combined axial and radial dark field image are each acquired after the pharmaceutical cylindrical container is rotated in an increment between 0.5° and 4°.
15. An apparatus for inspecting a pharmaceutical cylindrical container made of glass or polymer, the apparatus comprising:
a support device configured to support the pharmaceutical cylindrical container and rotate the pharmaceutical cylindrical container around a longitudinal axis;
a light receiving unit comprising a main camera configured to acquire an image of the pharmaceutical cylindrical container; and
a light emitting unit comprising, with respect to the main camera, a bright field light source, a radial dark field light source, and an axial dark field light source,
wherein the control unit controls to disregard any container having a defect with a property selected from a group consisting of: a size of 200 μm; a size of 100 μm or more; a size of 80 μm or more; a size of 50 μm or more; a size of 40 μm or more; a size of 20 μm or more; a size of 16 μm or more; a metallic defect on a surface of the pharmaceutical cylindrical container; a non-metallic defect on a surface of the pharmaceutical cylindrical container; a bubble within a wall or on a surface of pharmaceutical cylindrical container; a metallic defect within a wall of pharmaceutical cylindrical container; a non-metallic defect within a wall of the pharmaceutical cylindrical container; and any combinations thereof.
16. The apparatus of claim 15 , wherein the control unit is configured to generate a 3D image from the image, the 3D image showing defects on an inner surface of the pharmaceutical cylindrical container, an outer surface of the pharmaceutical cylindrical container, and within a wall of the pharmaceutical cylindrical container.
17. The apparatus of claim 15 , wherein the control unit configured to control the support device, the light emitting unit, and the light receiving unit to acquire a plurality of images of the pharmaceutical cylindrical container when only the bright field light source is activated and only when both the axial and radial dark field light sources are activated.
18. The apparatus of claim 1 , wherein the control unit is configured to generate a 3D image from the plurality of images, the 3D image showing defects on an inner surface of the pharmaceutical cylindrical container, an outer surface of the pharmaceutical cylindrical container, and within a wall of the pharmaceutical cylindrical container.
19. The apparatus of claim 1 , wherein the plurality of images comprise images taken when only the bright field light source is activated and only when both the axial and radial dark field light sources are activated.
20. The method of claim 13 , further comprising generating a 3D image from the plurality of images, the 3D image showing defects on an inner surface of the pharmaceutical cylindrical container, an outer surface of the pharmaceutical cylindrical container, and within a wall of the pharmaceutical cylindrical container.
21. The method of claim 13 , wherein the plurality of images comprise images taken when only the bright field light source is activated and only when both the axial and radial dark field light sources are activated.