Accurate manual illumination inspection

• US 5,940,176 A
• Filed: 09/16/1996
• Issued: 08/17/1999
• Est. Priority Date: 09/16/1996
• Status: Expired due to Term

• Current Assignee: Julius Z. Knapp
• Original Assignee: Julius Z. Knapp
• Inventors: Knapp, Julius Z.
• Primary Examiner(s): Rosenberger, Richard A.
• Application Number:
  US08/714,232
• Time in Patent Office: 1,065 Days
• Field of Search: 356/427, 356/240, 362/32, 362/125, 362/249
• US Class Current: 356/239.4
• CPC Class Codes: G01N 21/8803 Visual inspection measuring projectors G01B9/08
• CPC Class Codes: G01N 21/8806 Specially adapted optical and illumination features
• CPC Class Codes: G01N 21/9027 in containers after filling

Abstract

A method and device for the accurate manual inspection of three-dimensional (not flat) samples, such as pharmaceutically injectable vials, for particle contamination, which samples are illuminated with diffused (non-point) light. Opposing vertically positioned and spaced illumination sources are provided above and below the vial, with the vial being positioned in an inspection volume at the illumination midpoint (lumen light balance) between the illumination sources. The illumination midpoint, for light sources of equal intensity, is also the physical midpoint therebetween. Though the mid-point is not the position of maximum illumination for light sources, normal variation in manual inspections, e.g., variations in inspector height and deviations caused by manual handling of the vial, at the mid-point, result in minimal deviations in illumination, with resulting greater accuracy and replicability of inspection results. The station further optionally includes a light-dark-light changeable background for inspection of different contrast particles which may be in the vial, without removal of the vial from the inspection point at the illumination midpoint.

Claims

1. A method for enhancing the reliability of an illuminated inspection of defects in three dimensional items in an inspection station wherein the inspection station comprises an illumination source positioned on one side of an inspection volume in which a three dimensional item is positioned, and which inspection volume is visually aligned with an inspector for inspection with illumination from the illumination source;

said method comprising the steps of;

a) providing a second illumination source on a second side of the inspection volume substantially directly opposite that of the first illumination source and substantially in line therewith;

b) substantially visually aligning the inspection volume with an illumination midpoint between the illumination source positioned on one side of the inspection volume and the second illumination source positioned on the side substantially opposite to the first illumination source relative to the inspection volume; and

c) directly illuminating the three dimensional object with the respective illumination sources only with light therefrom which is in a substantially direct line between the respective illumination sources.

2. The method of claim 1, wherein additional illumination sources are positioned around the illumination midpoint with illumination symmetry.

3. The method of claim 1, wherein the inspection is visually conducted by a human.

4. The method of claim 1 wherein the inspection is conducted with the optical input of a machine vision system.

5. The method of claim 1, wherein the three dimensional item is a transparent vial containing an injectable solution and wherein the inspection station is provided with a changeable background behind the inspection volume relative to the inspector, wherein the background is changed from dark to light and light to dark for selective illuminated inspection of dark and light particles which may be contained in said injectable solution without moving the vial from the inspection volume.

6. The method of claim 5, wherein the inspection volume includes a volume to contain movement of the vial to place particles, which may be contained therein, into motion.

7. The method of claim 1, wherein the distance between the respective light sources is at least 20 inches and wherein illumination intensity from both light sources at the inspection volume is at least 250 foot-candles.

8. The method of claim 1, wherein both light sources are of substantially equal intensity and wherein the inspection volume is located substantially at the physical midpoint between the respective light sources.

9. The method of claim 1 wherein the three dimensional object is positioned within the inspection volume wherein light from the light sources which illuminates the inspection volume does not vary by more than 10%.

10. An inspection station for illuminated inspection of three dimensional items for defects therein, with enhanced reliability, wherein the inspection station comprises an illumination source positioned on one side of an inspection volume in which a three dimensional item is positioned, and which inspection volume is visually aligned with an inspector for human inspection with illumination from the illumination source;

characterized in that the inspection station further comprises a second illumination source on a second side of the inspection volume substantially directly opposite that of the first illumination source and substantially in line therewith;

wherein the inspection volume is substantially aligned with an illumination midpoint between the illumination source positioned on one side of the inspection volume and the second illumination source positioned on the side substantially opposite to the first illumination source relative to the inspection volume;

whereby there is direct illumination of the three dimensional object by the respective illumination sources only with light therefrom which is in a substantially direct line between the respective illumination sources.

11. The inspection station of claim 10, wherein additional illumination sources are positioned around the illumination midpoint with illumination symmetry.

12. The inspection station of claim 10, wherein the three dimensional item is a transparent vial containing an injectable solution and wherein the inspection station comprises means for selectively changing the background behind the inspection volume relative to the inspector, from dark to light and light to dark for selective illuminated inspection of dark and light particles which may be contained in said injectable solution, without moving the vial from the inspection volume.

13. The inspection station of claim 12, wherein the inspection volume includes a volume to contain movement of the vial to place particles, which may be contained therein, into motion.

14. The inspection station of claim 10, wherein the distance between the respective light sources is at least 20 inches and wherein illumination intensity from both light sources at the inspection volume is at least 250 foot-candles.

15. The inspection station of claim 10, wherein both light sources are of substantially equal intensity and wherein the inspection volume is located substantially at the physical midpoint between the respective light sources.

16. The inspection station of claim 10, wherein a magnifying lens is interposed between the inspector and the inspection volume.

17. The inspection station of claim 10, wherein a machine vision magnification system is interposed between the inspector and the inspection volume.

18. An inspection station for illuminated inspection of three dimensional items, for defects therein, with enhanced reliability, wherein the inspection station comprises an illumination source positioned on one side of an inspection volume in which a three dimensional item is positioned, and which inspection volume is visually aligned with any one of automated and manual inspection means for inspection with illumination from the illumination source;

characterized in that the inspection station further comprises a second illumination source on a second side of the inspection volume substantially directly opposite that of the first illumination source and substantially in line therewith;

wherein the inspection volume is substantially aligned with an illumination midpoint between the illumination source positioned on one side of the inspection volume and the second illumination source positioned on the side substantially opposite to the first illumination source relative to the inspection volume whereby the three dimensional object is illuminated with the respective illumination sources only with light therefrom which is in a substantially direct line between the respective illumination sources.

19. The method of claim 18, wherein additional illumination sources are positioned around the illumination midpoint with illumination symmetry.

20. The inspection station of claim 18, wherein the inspection volume is sized such that light from the light sources does not deviate within the inspection volume by more than 10%.