SYSTEM AND METHOD FOR AUTOMATIC INSPECTION OF INJECTION SYRINGES ON THE BASIS OF MACHINE VISION
원문보기
IPC분류정보
국가/구분
United States(US) Patent
공개
국제특허분류(IPC7판)
G06T-007/00
G06T-007/70
G06T-007/90
출원번호
US-0523365
(2015-10-15)
공개번호
US-0256049
(2017-09-07)
우선권정보
CN-201410597857.6 (2014-10-31)
국제출원번호
PCT/CN2015/091957
(2015-10-15)
발명자
/ 주소
YANG, Jibin
출원인 / 주소
JB MEDICAL, INC.
인용정보
피인용 횟수 :
0인용 특허 :
0
초록▼
A machine vision based automatic needle cannula inspection system and methods of use. The system comprises of an inspection and control unit, image capture devices (32, 33), light sources (34, 35, 36, 37), a unit that makes the needle cannula (28) and the image capture device(s) (32, 33) rotate rela
A machine vision based automatic needle cannula inspection system and methods of use. The system comprises of an inspection and control unit, image capture devices (32, 33), light sources (34, 35, 36, 37), a unit that makes the needle cannula (28) and the image capture device(s) (32, 33) rotate relative to each other, and a rejected part removal unit. By means of rotating the needle cannula (28) and image capture devices (32, 33) relatively, a plurality of images captured along the circumferential direction of the needle cannula are directly saved to a computer, the images are then screened, processed and analyzed to fulfill the automatic inspection of multiple quality and technical parameters of the needle cannula without the need to position the bevel area of cannula tip to a specific direction. Inspection parameters and accuracy can be set at any time, the system can automatically record classification and statistics of passed and rejected needle cannulae for query, and the rejected cannulae are removed automatically at next position. All the functions are completed at one work station, and needle cannula tips on both sides can be inspected simultaneously, if needed. Thereby the inspection efficiency and reliability are greatly improved, resulting in extremely extensive application prospects and huge economic values.
대표청구항▼
1. A machine vision based automatic needle cannula inspection system comprising: An inspection and control unit, to establish and realize its synchronized control and information processing with all other units of the automatic inspection system,and one of the following items a, b or c:a. A needle c
1. A machine vision based automatic needle cannula inspection system comprising: An inspection and control unit, to establish and realize its synchronized control and information processing with all other units of the automatic inspection system,and one of the following items a, b or c:a. A needle cannula holding and positioning unit, to separate, position and hold the needle cannula and to be able to keep the said needle cannula in position while the said needle cannula is driven to rotate; A needle cannula driving unit, to rotate the said needle cannula;Fixed image capture device(s), to capture images of rotating needle cannula driven by the said needle cannula driving unit while synchronized and controlled by the said inspection and control unit;b. A needle cannula holding, positioning and rotating unit, to separate, position, hold and rotate the said needle cannula and to be able to keep the said needle cannula in position; Fixed image capture device(s), to capture images of rotating needle cannula while synchronized and controlled by the said inspection and control unit;c. A fixed needle cannula holding and positioning unit, to separate, position and hold the said needle cannula; Image capture device(s) rotating around the said needle cannula, to capture images of the said fixed needle cannula while rotating around the said needle cannula and synchronized and controlled by the said inspection and control unit. 2. A needle cannula inspection system according to claim 1, wherein the said needle cannula holding and positioning unit is a cannula wheel device, or linear stepper tool bars, or a linear stepper belt; Said needle cannula driving unit is a power-driven rotating belt system, or a power-driven rotating wheel, which enables the said fixed image capture device(s) to capture images of rotating needle cannula driven by the said needle cannula driving unit while synchronized and controlled by the said inspection and control unit. 3. A needle cannula inspection system according to claim 1, wherein the said needle cannula holding, positioning and rotating unit is a device that can separate, position, hold and rotate the said needle cannula and to be able to keep the said needle cannula in position, so that the said fixed image capture device(s) can capture images of rotating needle cannula while synchronized and controlled by the said inspection and control unit. 4. A needle cannula inspection system according to claim 1, wherein said fixed needle cannula holding and positioning unit is a cannula wheel device, or linear stepper tool bars, or a linear stepper belt, or any device that can individually separate and fix the said needle cannula; Said image capture device(s) rotating around the said needle cannula is a system that rotates around the said needle cannula when driven by power and is capable of keeping the image capture device(s) focused on said needle cannula while capturing images and synchronized and controlled by the said inspection and control unit. 5. A needle cannula inspection system according to claim 2, wherein, on both sides of the circumferential edge of the said cannula wheel, or on top of the said linear stepper tool bars or the said linear stepper belt, there are uniformly and symmetrically set teeth, between two adjacent teeth there is a tooth groove or slot where said needle cannula to be inspected is placed in, each tooth groove or slot is placed at most one said needle cannula, said cannula wheel only rotates forward one tooth at a time or the said linear stepper tool bars or the said linear stepper belt only move forward one tooth at a time. 6. A needle cannula inspection system according to claim 5, wherein said power-driven rotating belt system or said power-driven rotating wheel is placed above the said cannula wheel or the said linear stepper tool bars or linear stepper belt, forming an engagement area with said cannula wheel or on the said linear stepper tool bars or linear stepper belt in which said power-driven rotating belt or power-driven rotating wheel is pressed onto the said needle cannula near the bottom of tooth grove or slot, when the said belt or wheel is driven to rotate, it will drive the said needle cannula to rotate, said engagement area is a cylindrical area whose diameter is on the circumference of the bottom of said tooth grooves or slots of said cannula wheel, or a plane whose height is the same as the bottom of tooth grooves or slots on said linear stepper tool bars or linear stepper belt, the width of said power-driven rotating belt or power-driven rotating wheel is slightly less than the width of the said engagement area. 7. A needle cannula inspection system according to claim 1, wherein a plurality of images are captured while said image capture device(s) and said needle cannula rotate relatively for a whole circle. 8. A needle cannula inspection system according to claim 7, wherein said image capture device(s) and said needle cannula rotate relatively at a constant speed and a plurality of images are captured at equal intervals for a whole circle. 9. A needle cannula inspection system according to claim 1, wherein said image capture device(s) could be double image capture devices. 10. A needle cannula inspection system according to claim 1, wherein the system further comprises a rejected part removal unit. 11. A needle cannula inspection system according to claim 10, wherein said inspection and control unit is a computer, said image capture device is at least one camera, said inspection and control unit is connected with said image capture device(s), motors of said needle cannula holding and positioning unit or said needle cannula holding, positioning and rotating unit or said fixed needle cannula holding and positioning unit, and said rejected part removal unit respectively with synchronized control settings. 12. A machine vision based automatic needle cannula inspection method comprising: By rotating said needle cannula relative to said image capture device(s), a plurality of images are captured along the circumferential direction of said needle cannula for a whole circle;Various quality and technical parameters of said needle cannula are inspected through screening, processing and analyzing the captured images. 13. A needle cannula inspection method according to claim 12, wherein a plurality of images are captured along the circumferential direction of said needle cannula at equal intervals continuously for a whole circle. 14. A needle cannula inspection method according to claim 12 comprises the following steps: (1) Select and adjust said image capture device(s), lenses and light sources based on the dimension of said needle cannula and set parameters such as distance, aperture and exposure time to capture clear images;(2) Set the accuracy and threshold for each inspection parameter;(3) Connect said computer with said image capture device(s), motors of cannula wheel device or linear stepper tool bars or linear stepper belt and said rejected part removal unit respectively with synchronized control settings. 15. A needle cannula inspection method according to claim 14 comprises further the following steps: (4) Said cannula wheel step rotates forward, or said linear stepper tool bars or linear stepper belt step moves forward;(5) Each tooth groove or slot of said cannula wheel or linear stepper tool bars or linear stepper belt is placed with one needle cannula;(6) Said cannula wheel or linear stepper tool bars or linear stepper belt pauses when the bevel area of said needle cannula in the tooth groove or slot is within the focus position of said image capture device;(7) Said power-driven rotating belt system or said power-driven rotating wheel above the said cannula wheel or linear stepper tool bars or linear stepper belt automatically presses onto the said needle cannula in the tooth groove or slot, and drive the said needle cannula to rotate;(8) Said computer sends a signal to start said image capture device(s);(9) Under illumination of said light sources, a plurality of images are captured at equal intervals while said image capture device(s) and said needle cannula rotate relatively at a constant speed for a whole circle, said images are saved to said computer, processed with machine vision techniques, and whether the needle cannula passes the inspection is recorded. 16. A needle cannula inspection method according to claim 12, wherein multithreading techniques and double image capture devices can be used to inspect both bevel areas at each end for needle cannula with bevel areas at both ends simultaneously. 17. A needle cannula inspection method according to claim 14, wherein said cannula wheel step rotates forward one tooth at a time, or said linear stepper tool bars or linear stepper belt step moves forward one tooth at a time. 18. A needle cannula inspection method according to claim 12, wherein conventional graying, filtering, binarization and rough edge extraction are processed on saved images. 19. A needle cannula inspection method according to claim 15 comprises further the following step: (10) Rejected needle cannula is blown off by compressed air of the rejected part removal device while qualified needle cannulae advance with said cannula wheel or linear stepper tool bars or linear stepper belt into the next process. 20. A needle cannula inspection method according to claim 19 further comprises the following step: (11) Upon completion of said needle cannula rotating relative to said image capture device(s) for a full circle and image capture process, said cannula wheel or linear stepper tool bars or linear stepper belt controlled by the computer signal advances one tooth and wait for the computer signal to start the image capture device(s) on next needle cannula. 21. A needle cannula inspection method according to claim 12, wherein a plurality of images captured on one bevel area of said needle cannula are processed to inspect at least one of the following quality and/or technical parameters: (a) Burrs on bevels and needle tip sharpness;(b) Inward or outward curved needle tips;(c) Accuracy of several bevel angles of needle cannula tip area;(d) Length of needle cannula. 22. A needle cannula inspection method according to claim 21, wherein the inspection on needle burrs on bevels and tip sharpness by processing and analyzing a plurality of images captured on one bevel area of said needle cannula comprises the following steps: (1) Among all the images captured around a full needle cannula circumference on one tip area, choose the one image with largest bright area; then perform accurate continuous area extraction, contour extraction, curve fitting and ellipse fitting to obtain ideal inner contour, outer contour and burrs;(2) When the burr's dimension, if any, exceeds the preset threshold, the needle cannula is disqualified;(3) Perform linear fitting of the upper portion of the bright area's outer contour, the two straight lines form an intersection above the needle tip, if the distance between the said intersection and the uppermost point of the bright area exceeds the preset threshold, the needle cannula is disqualified. 23. A needle cannula inspection method according to claim 21, wherein the inspection on inward or outward curved needle tips by processing and analyzing a plurality of images captured on one bevel area of said needle cannula comprises the following steps: First identify the image with largest bright area as in previous steps, then count forward or backward a number of images, the number is nearest to one-forth of total number of images, in other wards, choose the image that is approximately 90 or 270 degrees to the image with largest bright area; this image is almost the side view of the needle cannula; perform linear fitting of the left and right vertical lines; if the distance between the top point of the longest vertical line and horizontally the leftmost pixel or rightmost pixel exceeds the preset threshold, the needle cannula has a curved tip and is disqualified. 24. A needle cannula inspection method according to claim 23, wherein the inspection on accuracy of several bevel angles of needle cannula tip area by processing and analyzing a plurality of images captured on one bevel area of said needle cannula comprises the following steps: Using the same method as in claim 23, perform linear fitting on a few lines in the bevel area, angles formed between the cannula outer line and fitted lines can be calculated. Accuracy of bevel angles can be decided by comparing with preset threshold; by processing the image of near 180 degrees to this image, the accuracy of bevel angles on the other side can also be inspected. 25. A needle cannula inspection method according to claim 21, wherein the needle cannula length can be calculated when both ends of the needle cannula are inspected and the distance between camera A and camera B is calibrated, thus the needle cannula length can be inspected by comparing with preset threshold. 26. A needle cannula inspection method according to claim 21, wherein the needle cannula length can be calculated when only one end of the needle cannula is inspected, the other end is in a fixed position and the distance between camera and the other end is calibrated, thus the needle cannula length can be inspected by comparing with preset threshold. 27. A needle cannula inspection method according to claim 21, wherein the system can automatically record classification and statistics of passed and rejected cannulae for query. 28. A needle cannula inspection method according to claim 12, wherein a plurality of images captured along the circumferential direction of said needle cannula for a whole circle can be used to build a three-dimensional model, with which quality and technical parameters can be inspected.
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