Description:Field of the Invention

[0001] The present invention relates to a system for inspecting medicinal vials. More specifically, the present invention relates to an automated vial inspection system capable of detecting a range of defects in vials used for medicinal storage.

Background of the Invention

[0002] Generally, existing bottle inspection systems face several limitations in accuracy and efficiency. Conventional entry and exit conveyors often struggle with consistent vial spacing and alignment, causing inspection delays and missed defects. The inspection stations in these systems typically lack comprehensive 360-degree coverage, relying on fewer cameras with poorly positioned light sources that lead to incomplete inspections. This results in critical defects going undetected, particularly in areas like vial caps, seals, or actuator components. Furthermore, many systems lack sophisticated lighting, leading to glare or shadows that obscure visual inspections.

[0003] Automated vial flipping mechanisms in traditional machines are often inconsistent or non-existent, making it difficult to inspect essential areas like the dip tube. Systems without proper flipping rely on stationary cameras, which are not effective for inspecting the bottom surfaces or dip tubes. Additionally, inspection systems used for defects like dip tube damage or contamination are often rudimentary, relying heavily on manual inspection, which increases error rates and reduces overall inspection accuracy. Speed adjustment and synchronization of flipping mechanisms with conveyor speeds are also commonly absent, leading to jams or inefficient inspection flows.

[0004] Rejection systems in conventional machines are often outdated, using mechanical arms that risk damaging vials. These systems may not reorient vials before ejection, increasing handling issues. Moreover, a lack of automation in rejection bin monitoring can lead to overflows, causing further disruptions. Detection of contaminants like particulate matter is often overlooked, as existing systems lack a sufficient number of cameras required for thorough inspection. The absence of real-time monitoring and adjustment systems results in frequent line interruptions for recalibration when inspecting vials of varying sizes.

[0005] Lastly, many traditional systems have inadequate reporting, lacking automated capabilities to generate critical defect, batch, or audit reports. Without audible alarms or beacon lights to signal machine statuses or emergencies, operators may not respond to faults in time, leading to extended downtimes. Outdated sensor technology compounds these inefficiencies, failing to detect vial positions accurately or manage the flow of vials into pre-defined groups, further slowing production. These limitations contribute to increased operational costs and lower overall inspection quality.

[0006] Therefore, there is a need for a system for vial inspection that overcomes all the problems of the existing prior art.

Objects of the Invention

[0007] An object of the present invention is to provide a system for vial inspection.

[0008] Another object of the present invention is to provide a system for vial inspection that provides cost-effective solutions over existing systems in market.

[0009] Yet another object of the present invention is to provide a system for vial inspection that provides a less complex structure.

[0010] Further object of the present invention is to provide a system for vial inspection that inspects vial with multiple factors.

[0011] Furthermore, the object of the present invention is to provide a system for vial inspection that provides quick automated inspection of the vial.

Summary of the Invention
[0012] According to the present invention, there is a system for vial inspection. The system may include a conveyor for transporting vials into and out of the inspection area. The system may have at least one inspection station which may be equipped with multiple cameras and an LED light source, arranged around the vial at predetermined 120-degree interval angles to provide a full 360-degree view. This setup is used to detect defects in the vial. Additionally, the system may have a flipper mechanism configured to grip the vial from the conveyor and rotate it 180 degrees, flipping it upside-down to expose the dip tube for further inspection. Further, to capture the dip tube of the vial the system may have a side-positioned camera placed adjacent to the flipper mechanism to capture images of the vial’s dip tube and bottom surface after flipping. The system may include a detection system that is designed to determine the presence of the dip tube, identify any damage, measure the length of the dip tube, and detect similar issues, and there may be a rejection system is also present to eject defective vials based on the inspection results, with the flipper re-orienting the vial upright before transferring it to the rejection system. The rejected vial goes to a rejection bin which collects defective vials, and a bin-full sensor detects the level of the rejected vials.

[0013] In an aspect of the present invention, the system for vial inspection includes the detection system that is capable of identifying defects not only in the dip tube but also in other critical areas. These include defects in the vial itself, the vial cap, the dip tube, the actuator, and the seal. Moreover, the detection system can also identify contamination inside the vial, ensuring comprehensive inspection of the entire vial and its components.

[0014] Another aspect of the present invention, the flipper mechanism that includes both a pivoting arm and a gripping assembly. The gripping assembly is adjustable, allowing it to accommodate vials of various sizes without the need for part changes. This adjustability increases the flexibility and efficiency of the inspection process, as the system can handle different vial dimensions without additional downtime for mechanical adjustments.

[0015] In another aspect of the present invention, the flipper mechanism is designed to adjust its flipping speed based on the weight and size of the vial. The speed of the flipping operation can be synchronized with the speed of the conveyor, ensuring continuous and uninterrupted processing of the vials through the inspection area. This synchronization helps maintain a steady flow of vials, preventing bottlenecks and ensuring efficient operation.

[0016] In another aspect of the present invention, the system for vial inspection may include a lower-positioned camera designed to detect the presence of foreign contaminants within the vial including particulate matter that could compromise the quality of the product. The lower-positioned camera ensures that the inspection process covers not only external defects but also internal contamination that could affect product safety and integrity.
[0017] In another aspect of the present invention, the system for vial inspection may be equipped with an adjustable guide positioned at the entry point of the inspection area. This guide may be adjusted using a single knob, allowing operators to quickly center vials of varying diameters. This feature ensures that vials are properly aligned before they enter the inspection area, improving the accuracy and consistency of the inspection process.

[0018] In another aspect of the present invention, the system for the vial inspection mat includes a reporting system capable of generating a variety of reports. These reports may be product-wise, batch-wise, and defect-wise, and include audit trails and alarm reports. This comprehensive reporting system provides valuable insights into the performance of the inspection process, enabling better quality control and traceability for both production and regulatory purposes.

[0019] In another aspect of the present invention, the system for vial inspection may feature an audible alarm system and a three-colored beacon light. These components are designed to signal the operational status of the system, indicating normal operation, fault detection, and emergency stop conditions. The audible alarm and visual beacon light ensure that operators are quickly alerted to any issues, minimizing downtime and ensuring the smooth operation of the system.

[0020] In another aspect of the present invention, the system for vial inspection may utilize a rejection system that includes an air pressure sensor. This sensor controls the ejection of defective vials by applying a burst of air to remove them from the conveyor into the rejection bin. This air-based rejection method reduces the risk of damaging the vials during the ejection process and ensures that defective vials are effectively separated from the production line.

[0021] In another aspect of the present invention, the system for vial inspection may incorporate a traffic management mechanism that organizes vials into predefined groups for processing. These mechanisms help to ensure accurate detection, alignment, and efficient handling of vials throughout the inspection process.

Brief Description of the Drawings

[0022] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.

[0023] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description applies to any one of the similar components having the same first reference label irrespective of the second reference label.

[0024] The advantages and features of the present invention will be understood better with reference to the following detailed description and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which:

[0025] Figure 1 shows a side view of a system for vial inspection in accordance with the present invention;

[0026] Figure 2 shows a front view of a turn table of the system for vial inspection in accordance with the present invention;

[0027] Figure 3 shows a side view of the first traffic management mechanism of the system for vial inspection in accordance with the present invention;

[0028] Figure 4 shows a side view of a first and second inspection station of the system for vial inspection in accordance with the present invention;

[0029] Figure 5 shows a top view of the first inspection station of the system for the vial inspection in accordance with the present invention;

[0030] Figure 6 shows a side view of a first ejection and rejection mechanism of the system for vial inspection in accordance with the present invention;

[0031] Figure 7 shows a side view of a flipper mechanism of the system for vial inspection in accordance with the present invention;

[0032] Figure 8 shows a side of a flipper mechanism of the system for vial inspection in accordance with the present invention;

[0033] Figure 9 shows a side view of a second ejection and rejection mechanism of the system for vial inspection in accordance with the present invention;

[0034] Figure 10 shows a side view of a lifting mechanism of the system for vial inspection in accordance with the present invention;

[0035] Figure 11 shows various defects in the vials detected by a first inspection station, second inspection station, and third inspection station in accordance with the present invention; and

[0036] Figure 12 shows various defects of the vials detected by the third inspection station and a fourth inspection station in accordance with the present invention.

Detailed Description of the Invention

[0037] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The disclosed embodiments merely exemplars the invention, which may be embodied in various forms. The embodiments are in such detail as to communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.

[0038] The present invention relates to a system for vial inspection. The system includes a conveyor for transporting the bottles from one point to another. The system further includes an inspection station for inspecting the bottle from different angles to detect any defect on the bottle or the attached part of the bottle. Further, a rejection system is arranged within the system to eject the defective bottle from the system.

[0039] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0040] Referring now figure 1 of a system (100) for vial inspection in accordance with the present invention is illustrated. The system (100) for vial inspection is hereinafter referred to as “the system (100)”. The system (100) includes a body (100a), a conveyor (120), a plurality of inspection stations, and a detection system (180).

[0041] The system (100) includes a main body, the main body covering entirely from the start to end of the conveyor (120). The main body includes a control panel (111) arranged on a side panel of the main body. The control panel (111) includes a plurality of manual switches providing a plurality of control to the operating person. Further, an interactive screen (111a) is arranged within the control panel to show internal data of the system (100) including a control feature to allow the operating person to control the system (100) by interacting with the screen. The system (100) provides two control options to the operating person, the manual switch and the interactive screen in case of failure of one of them. The control panel (111) is integrated with a processor (not shown), the processor is configured to analyse all the data of the system (100) and control the system (100) function according to the data. It is obvious for the person skilled in the art to configure a number of manual switches and the interactive screen (111a) and alike to control the plurality of the function not limited to the working of the system (100) or speed of the system (100) or alike within the control panel (111).

[0042] The conveyor (120) is arranged within the system (100) for transporting bottles/vials (101) to and out of an inspection area of the system (100). The vial (101) is a small glass or plastic vessel or bottle, often used to store medication in the form of liquids, powders, or capsules. In the present embodiment, the vial (101) includes a cap, seal, dip tube (101a), and an actuator. The conveyor (120) is arranged from the start to the end of the system (100). The conveyor (120) includes a belt which is attached chain sprocket mechanism (not shown), the chain is movably connected to the sprocket which is connected to an electric motor (not shown). The electric motor rotates the sprocket to move the conveyor belt of the system (100) to transport the vials (101) from one end to another end of the system (100). In the present embodiment, the system (100) includes the conveyor belt with chain sprocket and electric motor to transport the vials (101). In another embodiment, the system (100) may be equipped with a pneumatic, hydraulic, roller, or vibratory conveyor arranged to transport the vial (101) from one point to another point of the system (100). In another embodiment, the system (100) may include chutes and gravity-fed systems in which the materials slide down inclined planes, ramps, or spiral chutes due to gravity. In another embodiment, a robotic arm may be arranged to transport the vials (101) within the system (100). In another embodiment, a vacuum suction pipe may be arranged to transport the vials (101) with suction force from one point to another point of the system (100). It is obvious for the person skilled in the art to configure any other alternative mechanism to transport the vials (101) within the system (100).

[0043] Referring now to fig 2, the system (100) includes a turn table (110) at the first end of the system (100). The turn table (110) rotates continuously at a predetermined speed with the help of an electric motor, an operating person can place the vials (101) on the turn table (110), and a frame (110a) is arranged over the turn table (110). The frame (110a) includes a flexible guide (102), the flexible guide arranged on an extended rod arranged on the center portion of the frame (110a). The rod is extended in a downward direction towards the surface of the turn table. The first end of the extended rod is first attached to the frame (110a) and the second end of the extended road includes the flexible guide strip to guide the vials (101) to the edge of the turn table (110).

[0044] The frame (110a) further includes a guide wall (104) arranged on the edge of the turn table (110). The guide wall (104) vertically aligns with the conveyor (120) of the system (100). The flexible guide (102) spreads the vials (101) to the edge of the turn table (110) and the guide wall (104) divides the multiple vials (101) coming from the edge of the turn table (110) into a single line of the vials (101) and guide the remaining vials (101) again to the turn table (110) to rotate again through the flexible guide (102). The single line of the vials (101) goes to the conveyer (120) for inspection. In the present embodiment, the vials (101) are placed on the turn table (110) manually, and the flexible guide (102) and the guide wall (104) guide the vials (101) to the conveyor (120) in a single line. In another embodiment, the system (100) may be arranged within the manufacturing line, where the manufactured vials (101) are coming through the single conveyor (120) in the system (100), without having the turn table (110). It is obvious for the person skilled in the art to configure the system (100) at any position with any alternative mechanism to transport the vials (101) throughout the system (100).

[0045] The system (100) includes an adjustable guide (not shown) positioned at the entry point of the inspection area, the adjustable guide being adjustable via a single knob (not shown) to center the vials (101) of varying diameters. The adjustable guide is arranged at the first end of the conveyor (120), and the adjustable guide centrelines the coming vials (101) on the conveyor (120). The adjustable guide includes the knob, arranged adjacent to the conveyor (120) allowing the operating person to adjust the gap between the adjustable guide by actuating the knob according to the size of the different vials (101) or bottles. In the present embodiment, the manual adjustable knob is arranged for adjusting the adjustable guide as per the size of the object. In another embodiment, the automatically adjustable guide may be arranged on the conveyor (120) having a spring-loaded mechanism on both sides of the guide, to adjust the gap between the guide according to the size of the object by actuating the spring mechanism. In another embodiment, a servo-controlled adjustable guide mechanism may be arranged to centreline the vials (101) and adjust them according to the size of the vials (101). It is obvious for the person skilled in the art to configure any mechanism to centrally guide the inkling vials (101) into the system (100).

[0046] The system (100) further includes a first traffic management mechanism (106) as shown in Fig 3, the first traffic management mechanism (106) is arranged within the conveyor (120) of the system (100). The first traffic management mechanism (106) is arranged adjacent to the adjustable guide. The first traffic management mechanism (106) includes a circular plate (106a) horizontally arranged on one side of the conveyor (120) and a rough portion (106b) is arranged on the other side of the conveyor (120). The circular plate (106a) is made of flexible rubber material with a smooth surface and the rough portion (106b) has a rough surface. The vials (101) pass between the circular plate (106a) and the rough portion (106b), and upon passing the vial (101) through the circular plate (106a) and the rough portion (106b) of the first traffic management mechanism (106) creates a predetermined gap between each of the vials (101) to inspect each vial (101) separately. The first traffic management mechanism (106) further includes an object sensor (not shown) to detect the vials (101) on the conveyor (120), the object sensor may be sensors photoelectric sensor, infrared sensors sensor, or laser sensor, detect the presence of products on the conveyor (120). It is obvious for the person skilled in the art to configure an alternative sensor or mechanism to detect the presence of vials (101). In the present embodiment, the first traffic management mechanism (106) is arranged to manage traffic between the vials (101) and create a specific distance between each vial (101) on the conveyor (120). In another embodiment, pneumatic pushers or diverters may be arranged which use compressed air to gently push products to specific gaps on the conveyor (120) or to stop them temporarily. In another embodiment, motorized gates or barriers can be installed on the conveyor (120) to manage traffic. It is obvious for the person skilled in the art to configure any mechanism or sensor to manage vial (101) traffic on the conveyor (120).

[0047] Referring now to figures 1 and 4, the system (100) includes a first inspection station (130) positioned on the conveyor (120). The first inspection station (130) includes a plurality of cameras and an LED light source positioned around the vial (101) at predetermined degree interval angles to provide a 360-degree inspection of the vial (101) for detecting defects. The first inspection station (130) detects in the vial (101) (as shown in figure 11) such as the presence of a cap, number of dip tubes (101a), actuator presence, crack or damage, or stained actuator, cut on the seal or alike. For example, if the vial (101) does not have a cap on the actuator or there is a cap with a cut or stain, such vials (101) will be considered defective.

[0048] The first inspection station (130) is made of an octagon-shaped body, which is covered from top and bottom, it is obvious for the person skilled in the art to configure the inspection station body with any shape or material as per the requirement. The conveyor (120) is passing through the first inspection station (130). The first inspection station (130) includes two openings (131a,131b) at the bottom end of the body of the first inspection station (130). The openings allow the vials (101) to enter and exit through the first inspection station (130). The first inspection station (130) includes three cameras arranged around the first inspection station (130) at a predetermined angle of 120 degrees, a camera opening arranged on the body for each camera arranged around the first inspection station (130). The first inspection station (130) includes a first camera (132) and a second camera (134), the first camera (132) and the second camera (134) are arranged on a first side of the conveyor (120). The first camera (132) and the second camera (134) are arranged at a 120-degree angle with each other. Also, the first inspection station (130) includes a third camera (136) which is arranged on a second side of the conveyor (120). The third camera (136) is arranged at angle of 120 degree with the first camera (132) and the second camera (134) configuring the first camera (132), the second camera (134) and the third camera (136) positioned at 120 angles from each other of the first inspection station (130) to provide 360-degree inspection of the vial (101) for detecting defects as shown in fig 5. The first camera (132), the second camera (134) and the third camera (136) are fixed around the first inspection station (130). The first camera (132), the second camera (134) and the third camera (136) facing towards the centre of the first inspection station (130) to capture the vials (101) passing therethrough. It is obvious for the person skilled in the art to configure any number of cameras at any position, with fixed or movable attachment to provide inspection of the vials (101) from 360-degree angle.

[0049] Further, the LED lights (130a, 130b,) are configured at the bottom of the first inspection station (130) to provide light during the inspection as the traffic management mechanism (106) creates predetermine distance between each vial (101) on the conveyor (120) then all the cameras (132,134,136) of the first inspection station (130) able to capture individual vial (101) at predetermine time to capture each vial (101) from 360 degree and the LED lights (130a,130b) also provides light source at the same time when the first camera (132), the second camera (134) and the third camera (136) capture the vials (101). The first inspection station (130) body has a reflective surface from the inside, to provide additional brightness in the inspection station (130) when the LED lights turn ON. It is obvious for the person skilled in the art to configure ant light with any specification with any configuration within the inspection station.

[0050] In another embodiment of the present invention, the first inspection station (130) includes a single camera slidably arranged on the inner wall of the first inspection station. When the vials (101) pass through the first inspection station the camera will slidably rotate in horizontal direction on the wall of the first inspection station to capture the vial (101) from 360-degree angle.

[0051] In another embodiment of the present invention, an omnidirectional mirror arranged on the inside wall of the inspection station. These mirrors can reflect multiple angles of the vial (101) into the camera’s view to prevent the use of the multiple cameras to capture the vials (101) from 360-degree angle.

[0052] In another embodiment of the present invention, a camera gantry arranged within the inspection station allowing the camera to move vertically or horizontally around the vial (101) to capture images from different angles.

[0053] It is obvious for the persons skilled in the art to configure number of cameras with any orientation or mechanism to capture the vials (101) from 360-degree angles.

[0054] In another embodiment of the present invention, the first inspection station (130) is integrated with a rotation table, the rotation table having an inbuilt carrier that aligns with the conveyor (120) to transport the vial (101). As the vial (101) enters in the first inspection station (130), the rotation table receives the vial (101) with the inbuild carrier, upon receiving the vial (101) the inbuild carrier of the turn table will stop and the vial (101) will be positioned at the center of the rotation table. Now the rotation table rotates each vial (101) at a 360-degree angle and there will be a single camera arranged at the wall of the first inspection station (130), that captures the vial (101) while the vial (101) rotates on the rotation table. As soon as the rotation of the 360-degree is complete the rotation table will stop and the inbuild carrier of the turn table will alight with the conveyor (120) and start to move in the same direction as the conveyor (120) of the system (100), and the vial (101) will move forward in the system (100). It is obvious for the person skilled in the art to configure any mechanism with any orientation with any number of cameras and the light to capture the vials (101) at a 360-degree angle.

[0055] The system (100) further includes a second inspection station (140) next to the first inspection station (130) arranged on the conveyor (120). The vials (101) go to the second inspection station (140) right after going through the first inspection station (130). The second inspection station (140) includes a plurality of cameras and an LED light source positioned around the vial (101) at predetermined degree interval angles to provide a 360-degree inspection of the vial (101) for detecting defects. The second inspection station (140) is made of an octagon-shaped body, which is covered from top and bottom, it is obvious for the person skilled in the art to configure the second inspection station with any shape or material as per the requirement. The conveyor is passing through the second inspection station (140). The second inspection station (140) includes two openings at the bottom end of the body. The openings allow the vials (101) to enter and exit through the second inspection station (140). The second inspection station (140) includes three cameras arranged around the second inspection station (140) at a predetermined angle of 120 degrees. The second inspection station (140) includes a camera opening on the body for each camera arranged around the second inspection station (140).

[0056] The second inspection station (140) includes a fourth camera (142) and a fifth camera (144) arranged at the second side of the conveyor (120) having an angle of 120-degree between each other, and a sixth camera (146) is arranged on the first side of the conveyor (120) having angle of 120 degree from the fourth camera (142) and the fifth camera (144) of the second inspection station (140) to provide 360-degree inspection of the vial (101) for detecting defects, the second inspection station (140) detect defects of the vial (101) (as shown in figure 11) such as spots and scratches on the vial (101), stains and dirty vials (101) or alike. For example, if the vial (101) body has any spots or scratches, such vials (101) will be considered defective.

[0057] The fourth camera (142), the fifth camera (144), and the sixth camera (146) are fixed around the second inspection station (140) facing towards the vials (101) on the conveyor (120). Further, the LED lights (not shown) are configured at the bottom of the second inspection station (140) to provide a light source during the inspection. It is obvious for the person skilled in the art to configure ant light with any specification with any configuration within the inspection station.

[0058] The fourth camera (142), the fifth camera (144), and the sixth camera (146) of the second inspection station (140) capture each vial (101) at a predetermined time to capture each vial (101) from 360 degrees and the LED lights also provides light source at the same time when the cameras capture the vials (101). The second inspection station (140) body has a reflective surface from inside, to provide additional brightness in the inspection station when the LED lights turn ON. The angle between the cameras within the first inspection station (130) and the second inspection station (140) is the same which is 120 degrees to each other. However, the positioning of the first inspection station (130) and the second inspection station (140) are complete opposites. As in the first inspection station (130), the first camera (132) and the second camera (134) are arranged on the first side of the conveyor (120) and the third camera (136) is positioned at the second side of the conveyor (120) which means two cameras at the first side and one camera at the second side of the conveyor (120). Where in the second inspection station (140), the fourth camera (142) and the fifth camera (144) are positioned at the second side of the conveyor (120) and the sixth camera (146) is positioned at the first side of the conveyor (120) which means two cameras positioned at the second side and the one camera positioned at the first side of the conveyor (120). The different positioning of the cameras in both inspection stations provides complete 360 inspections of each vial (101) to capture defective or damaged caps, molding, actuator, dip tub (101a), seal, or any kind of stain/dirt or scratch on the vial (101) and alike.

[0059] The detection system (180) is configured to analyze the captured photos of the vials (101) at different angles and positions. The detection system (180) is fed with the plurality of the defective vial (101) photos with all the angles and position with all the possible defects that can happen to the vial (101). The detection system (180) uses those defective vial (101) photos as the parameter, when the captured photos of the vials (101) go to the detection system (180), the detection system (180) compares the captured photos with the defective vial photos which is integrated within the detection system (180) as a parameter. If the detection system (180) finds any similarity within the captured photo of the vials with defective vial photos, that vial (101) gets rejected by the detection system (180).

[0060] In an aspect of the present invention, the system (100) includes a second target sensor (not shown) arranged within the conveyor (120) adjacent to the second inspection station (140). The detection system (180) detects the defective vial (101) and sends the signal to the second target sensor. The second target sensor set the target of that defective vial (101) on the conveyor (120) to eject the defective vial (101) from the conveyor (120). In the present embodiment, the target sensor is an ultrasonic sensor to detect the vial presence. In another embodiment, the target sensor may be a laser distance sensor to detect the presence of the vial (101). In another embodiment, the target sensor may be an inductive proximity sensor or photoelectric sensor or LIDAR sensor or magnetic sensor. It is obvious for a person skilled in the art to configure any sensor or mechanism to detect the presence of vial (101).

[0061] Referring now to fig 6, the system (100) includes a first ejection mechanism (148) arranged on the second side of the conveyor (120). The ejecting mechanism (148) includes the shoe (148a) position adjacent to the conveyor (120). The shoe is connected to the motor. Further, a first rejection bin (149) is arranged on the first side of the conveyor (120). The first ejection mechanism (148) and the first rejection bin (149) are positioned opposite to each other on the second side and the first side of the conveyor (120). The first rejection bin (149) includes an opening (149a) position opposite to the shoe (148a) of the first ejection mechanism (148). When the detection system (180), detects the defective vial (101), the signal goes to the processor and the processor sends the signal to the first ejection mechanism (148) to eject the defective vial (101) from the conveyor (120). The motor of the first ejection mechanism (148) actuates the shoe (148a) in the horizontal direction and the shoe (148a) pushes the defective vials (101) towards the opening (149a) of the first rejection bin (149), Further a bin full sensor (not shown) is arranged to detect the level of the bin. It is obvious for the person skilled in the art to configure any alternative mechanism to deploy the defective vials (101) from the conveyor (120).

[0062] Referring now to figure 7, the vials (101) arrive at a third inspection station (150). The third inspection station (150) includes a second traffic management mechanism (152) arranged on the conveyor (120) after the first ejection mechanism (148). The second traffic management mechanism (152) includes a movable portion arranged at the second side of the conveyor (120) and a fixed portion arranged at the first side of the conveyor (120). The movable portion and the fixed portion are arranged opposite to each other on the conveyor (120). The movable portion moves horizontally towards and away from the fixed portion. The second traffic management mechanism (152) holds one vial (101) on the conveyor (120) by actuating the movable portion toward the fix portion, till the other vials (101) on the conveyor (120) get close to the vial (101) which is locked between the movable portion and the fixed portion and makes the vial (101) group having seven vials (101). The vial (101) group goes further on the conveyor (120), and the conveyor (120) is configured with a stopper (154) which stops the vial (101) group on the conveyor (120). The stopper (154) on the conveyor (120) includes a second object sensor (not shown) to detect the presence of the vial (101) group.

[0063] The third inspection station (150) further includes a flipper mechanism (156) configured to grip the vial (101) group from the conveyor (120) and rotate the vial (101) group 180 degrees to flip it upside-down to expose the dip tube (101a) for inspection. The flipper mechanism (156) is positioned at the first side of the conveyor (120), configured with the movable chain mechanism (not shown) to allow the flipper mechanism (156) to move longitudinally parallel to the conveyor (120) on back-and-forth direction. The flipper mechanism (156) includes a pivoting arm (156a) and a gripping assembly (156b). The gripping assembly (156b) is adjustable to accommodate vials (101) of different sizes without part changes as the griping assembly (156b) is configured with one fixed gripper and a second movable gripper. The movable gripper moves towards the fixed gripper to hold the vial (101) group in between the fixed gripper and the movable gripper, the movable gripper allows the gripping assembly (156b) to hold different sizes of vials (101) without any modification.

[0064] The flipper mechanism (156) includes an electric motor (157) which is connected to the pivoting arm (156a) and the gripping assembly (156b). When the second object sensor sends the signal to the processor upon detecting the vial (101) group. The processor signals the electric motor (157) to actuate the pivoting arm (156a) towards the vial (101) group and the gripper assembly (156b) holds the vial (101) group with the help of the movable gripper. As soon as the gripper assembly (156b) holds the vial (101) group, the electric motor (157) again actuates the pivoting to actuate the pivoting arm (156a) away from the conveyor and flip the vial (101) group upside down at 180- degree angle. While the pivoting arm (156a) flips the vial (101) group upside down, the movable chain mechanism moves the flipper mechanism (156) away from the stopper (154) longitudinally parallel to the conveyor (120).

[0065] The third inspection station (150) includes a seventh camera (158) arranged at the second side of the conveyor (120) and an LED light (158a) arranged at the first side of the conveyor (120). The seventh camera (158) and the LED light (158a) are arranged opposite and facing each other. The flipper mechanism (156) flips the vial (101) group upside down at a 180-degree angle and the movable chain mechanism moves the flipper mechanism (156) towards the seventh camera (158). The flipper mechanism (156) stops between the seventh camera (158) and the LED light (158a). The seventh camera (158) captures the vial (101) group at the flipped position. The third inspection station (150) detects defects in the vial (101) (as shown in figures 11 and 12) such as the presence of the dip tube (101a), length of the dip tube (101a), orientation of the dip tube (101a), presence of the liquid in the vial (101), level of liquid in vial (101), or alike. For example, if the dip tube (101a) length inside the vial (101) is lesser/greater than the required length, such vials (101) will be considered defective.

[0066] The seventh camera (158) sends the captured photos to the detection system (180), and the detection system (180) analyse the captured photos of the vial (101) group and detects the faulty vial (101) related to dip tube (101a), or content level of the vial (101) or alike. As soon as the seventh camera (158) captures the vial (101) group, the electric motor (157) of the flipper mechanism (156) actuates the pivoting arm (156a) and pivotally rotates back 180-degree, and places the vial (101) group at the conveyor (120) as shown in figure 8. The vial (101) group moves forward on the conveyor (120).

[0067] Referring now to fig 9, the system (100) includes a second ejection mechanism (162) arranged on the second side of the conveyor (120), and a second rejection bin (164) is arranged on the first side of the conveyor (120). The second ejection mechanism (126) includes a pneumatic cylinder having a block arranged at the end of the pneumatic cylinder. The pneumatic cylinder actuates the block and the block pushes the vial (101) from the conveyor. The second rejection bin (164) includes an opening facing towards the block. As the block pushes the defective vial (101) away from the conveyor (120), the defective vial (101) goes to the second rejection bin (164) through the opening. In the present embodiment, the pneumatic cylinder with a block arranged to push the vial (101) away from the conveyor (120), it is obvious for the person skilled in the art to configure any alternative mechanisms to remove the defective vial (101) from the conveyor (120).

[0068] Referring now to fig 10, the vials (101) go to a fourth inspection station (160) of the system (100). The fourth inspection station (160) further includes a third traffic management mechanism (166). The third traffic management mechanism (166) holds the vial (101) on the conveyor (120) making a group of 7 vials (101), the fourth inspection station (160) includes a lifting mechanism (168). The lifting mechanism includes a gripping jaw (168a) arranged on both sides of the conveyor (120), the gripping jaw (168) arranged at the first side of the conveyor (120) and the second gripping jaw arranged at the second side of the conveyor (120). The gripping jaws (168a) are connected with a pneumatic mechanism, having pneumatic cylinders arranged at both sides of the gripping jaw. The fourth inspection station (160) includes a second stopper (169) that is movably arranged within the conveyor (120). The second stopper (169) is arranged adjacent to the lifting mechanism (166). Further, a third object sensor (not shown) is arranged within the fourth inspection station (160) adjacent to the lifting mechanism (168). The third object sensor detects the vial (101) group and indicates the processor of the system (100). The processor signals the second stopper (69) to stop the vial (101) group between the first jaw and the second jaw of the lifting mechanism (168). The lifting mechanism lifts the vial (101) group upon the conveyor (120), and then moves aside the vial (101) group at the second side of the conveyor (120).

[0069] The fourth inspection station (160) includes an eighth camera (170) arranged at the second side of the conveyor (120), the eighth camera (170) position facing the upside of the conveyor (120). When the lifting mechanism (168) lifts the vial (101) group and sideline the vial (101) group at the second side of the conveyor (120). The eighth camera (170) captures the vial (101) group from the base of the vial (101), an LED light (not shown) is also arranged along with the eighth camera (170), which provides the light source while capturing the vail group from the base. The eighth camera (170) of the system (100) captured the vial (101) from the base and shared the captured photo with the detection system (180). The fourth inspection station (160) detects defects in the vial (101) (as shown in Figure 12) such as damaged or stain/dirt or scratch on the base of the vial (101), and contamination within the vial (101) or alike. For example, if the vial (101) has any foreign particles, then the vial (101) is considered defective.

[0070] After capturing the vail group from the base, the lifting mechanism (168) moves the vial (101) again on the conveyor (120) of the system (100) and places the vial (101) group on the conveyor (120), when the lifting mechanism (168) place the vial (101) group on the conveyor (120), the second stopper (169) move aside from the conveyor (120) and the vial (101) group goes further on the conveyor (120). The detection system (180) analyses the captured photos from the eighth camera (170) and detects any crack, stain, contamination, or the like. Upon detecting any defect within the base of the vials (101), the detection system (180) sends the signal to the processor of the system (100).

[0071] The system (100) further includes a third ejection mechanism (172). The third ejection mechanism (172) is arranged on the second side of the conveyor (120), and a third rejection bin (174) is arranged on the first side of the conveyor (120). The third ejection mechanism (172) includes a pneumatic cylinder having a block arranged at the end of the pneumatic cylinder. The pneumatic cylinder actuates the block and the block pushes the vial (101) from the conveyor (120). The third rejection bin (174) includes an opening facing towards the block. As the block pushes the defective vial (101) away from the conveyor (120), the defective vial (101) goes to the third rejection bin (174) through the opening. In the present embodiment, the pneumatic cylinder with a block arranged to push the vial (101) away from the conveyor (120), it is obvious for the person skilled in the art to configure any alternative mechanisms to remove the defective vial (101) from the conveyor (120).

[0072] After rejecting the defective vials (101) from the conveyor (120), the vials (101) without any defect go further on the conveyor (120) for packing.

[0073] The system (100) further includes a reporting system. The reporting system is integrated to generate detailed, organized reports across various metrics essential for quality control and production monitoring. The reporting system can produce reports categorized by product type, batch, and specific defect types, enabling operators to identify patterns in defects, track production quality, and analyse performance. The reporting system maintains a history of the inspection data and process changes, ensuring traceability and compliance with regulatory standards. Additionally, alarm reports notify operators of any issues that arise during operation, facilitating rapid responses to potential problems and improving overall operational efficiency.

[0074] Further, an audible alarm with three colored beacons (190) is arranged on the system (100) to alert the operator. The alarm and beacon (190) provide a clear, real-time indication of the system’s (100) operational status. The three-colored beacon (190) light visually signals the system’s (100) condition, with distinct colors indicating normal operation, fault detection, and emergency stop conditions, ensuring that operators can quickly assess the system’s (100) status at a glance. The audible alarm further enhances alert functionality by providing a sound-based warning system, allowing operators to respond promptly to any malfunctions or emergencies.

[0075] Therefore, the present invention provides the advantage of the bottle inspection system (100) described. First, the use of a conveyor (120) system combined with a plurality of cameras positioned around the vial (101) enables a full 360-degree inspection of the vial (101), ensuring that defects such as damage to the vial (101), cap, dip tube (101a), actuator, and contamination within the vial (101) are accurately detected. The integration of the flipper mechanism (156) that rotates the vial (101) 180 degrees allows for the inspection of the dip tube (101a) and bottom surface, a feature that is particularly useful for detecting defects that may not be visible during standard inspection processes. This comprehensive inspection setup improves the accuracy and reliability of defect detection, ensuring that only quality products proceed to the next stages of packaging or distribution.

[0076] Additionally, the system (100) enhances efficiency by including an adjustable gripping assembly (156B) in the flipper mechanism (156), which allows it to accommodate vials (101) of different sizes without the need for part changes. The synchronized operation between the flipping mechanism (156) and the conveyor (120) ensures continuous processing, while the rejection system, including an air pressure sensor, effectively removes defective vials (101) from the line. The reporting system generates detailed, customizable reports for monitoring production batches, defects, and alarms, facilitating improved traceability and quality control. Moreover, the inclusion of visual and audible indicators, such as the three-colored beacon (190) light and an audible alarm, ensures that operators can monitor the operational status of the system (100) easily, further improving safety and operational management.

[0077] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
, Claims:We Claim:
1. A system (100) for vial (101) inspection, the system (100) comprising:
a conveyor (120) for transporting vials (101) into and out of an inspection area;
at least one inspection station (130, 140, 150, 160) comprising a plurality of cameras and at least one LED light positioned around each vial (101) at predetermined angular intervals to provide a circumferential imaging of the vial (101) for detecting defects;
a flipper mechanism (156) configured to grip each vial (101) from the conveyor (120), and rotate the vial (101) 180 degrees to flip it upside-down to expose a dip tube (101a) for inspection;
at least one side-positioned camera (158) arranged adjacent to the flipper mechanism (156) to capture images of the dip tube(101a) and a bottom surface of the vial (101) after the vial (101) has been flipped;
a detection system (180) configured to determine the presence of the dip tube (101a), identify damage to the dip tube (101a), and measure the length of the dip tube (101a);
at least one ejection mechanism (148, 162, 172) configured to eject defective vials (101) based on inspection results, wherein the flipper mechanism (152) re-orients each vial (101) upright after inspection before transferring it to the rejection system; and
at least one rejection bin (149, 164, 174) configured to collect defective vials (101), with a bin full sensor (not shown) to detect the level of the rejected vials (101).

2. The system (100) for vial (101) inspection as claimed in claim 1, wherein the detection system (180) detects defects to the vial (101), vial cap, dip tube (101a), actuator, seal, and contamination within the vial (101).

3. The system (100) for vial (101) inspection as claimed in claim 1, wherein the flipper mechanism (156) includes a pivoting arm (156a) and a gripping assembly (156b), wherein the gripping assembly (156b) is adjustable to accommodate vials (101) of different sizes without part changes.

4. The system (100) for vial (101) inspection as claimed in claim 1, wherein the flipper mechanism (156) is configured to adjust the speed of flipping based on the weight and size of the vial (101) and synchronize the flipping operation with the speed of the conveyor (120) to maintain continuous processing.

5. The system (100) for vial (101) inspection as claimed in claim 1, wherein the system (100) includes a lower-positioned camera is configured to detect the presence of foreign contaminants in the vial (101), including particulate matter.

6. The system (100) for vial (101) inspection as claimed in claim 1, wherein the system (100) includes an adjustable guide positioned at the entry point of the inspection area, the guide being adjustable via a single knob to center the vials (101) of varying diameters.

7. The system (100) for vial (101) inspection as claimed in claim 1, wherein the system (100) includes a reporting system configured to generate reports including product-wise, batch-wise, defect-wise, audit trail, alarm reports, and alike.

8. The system (100) for vial (101) inspection as claimed in claim 1, wherein the system (100) includes an audible alarm and a three-colored beacon (190) light, configured to signal the operational status of the system (100), including normal operation, fault detection, and emergency stop conditions.

9. The system (100) for vial (101) inspection as claimed in claim 1, wherein the rejection system includes an air pressure sensor configured to control the ejection of defective vials by applying a burst of air to remove them from the conveyor (120) into the rejection bin.

10. The system (100) for vial (101) inspection as claimed in claim 1, wherein the system (100) includes a plurality of sensors arranged within the inspection line of the system (100) including at least one traffic management mechanism (106,152,166) configured to arrange vials (101) into predefined groups for processing.