Using NI Vision & Motion for Automated Inspection of Medical Devices and Pharmaceutical Processes. Morten Jensen 2004

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1 Using NI Vision & Motion for Automated Inspection of Medical Devices and Pharmaceutical Processes. Morten Jensen, National Instruments Pittcon 2004 As more control and verification is needed in medical device testing, automated inspection is an effective way to ensure that devices and process meet stringent quality requirements. See how easy-to-use software tools coupled with flexible and powerful hardware creates an inspection system that lowers the cost of your verification. The NI Compact vision System combines the power of 3 smart camera in one package by using IEEE-1394 technology and a high performance processor. Use Vision Builder and LabVIEW to create an inspection system ideally suited to your specific application. 1

2 Traditional Vendor-Defined Instruments Customer-Defined PC-Based Measurement and Automation Solutions Processor RAM ROM Display Power Supply Hard Disk The virtual instrumentation paradigm has transformed test, measurement, and automation applications from loosely coupled and often incompatible stand-alone instruments and devices into tightly integrated, highperformance measurement and automation systems. At the heart of the virtual instrumentation paradigm lies a component that has become increasingly more important software. While the hardware advances in the personal computer have driven significant performance improvements and cost reductions compared to traditional stand-alone instruments, it is the highly productive, integrated software that empowers hundreds of thousands of engineers and scientists (Harvest the power of the PC). A complete set of software tools from measurement driver architectures and instrument connectivity software, to highly productive application development environments and open connectivity with standard tools across the enterprise gives engineers and scientists the freedom to create a new level of powerful, customized measurement systems. 2

3 ! "! # $ # % & # ' ( ) * +, - +, The ultimate in virtual instrumentation software, NI LabVIEW packages the power of a traditional programming language into an easy to use graphical development environment to increase your efficiency and reduce overall development time and cost. In general-purpose programming languages, the code is as much of a concern as the application. You must pay close attention to commas, periods, semicolons, square brackets, curly brackets, round brackets,. In contrast, with LabVIEW you use icons to represent functions, and you wire them together to determine the flow of data through your program, similar to creating flowcharts. It has all the breadth and depth of a general-purpose programming language, but it is easy to use, making you highly productive by decreasing the time required to develop your applications. 3

4 !!, & $ %, 3 %! $2 & / 01 $ / & % ) /. 1 & 1!., 7 8) +9 " + LabVIEW has moved from the workstation / desktop computer all they way to be embedded into stand alone systems. Eventually, we will see LabVIEW running on sensors, and the computer workstation will only be used to develop the system and monitor it. 4

5 : ; *, *, 88& & & : ;, & As more control and verification is needed in medical device testing, automated inspection is an effective way to ensure that devices and process meet stringent quality requirements. See how easy-to-use software tools coupled with flexible and powerful hardware creates an inspection system that lowers the cost of your verification. 5

6 $%, Camera or Other Measurement Device Image Acquisition Board Motion Controller Data Acquisition Device Software Motor Drive Motor or Stage $ Creating an automated measurement system involving motion control, machine vision, and data acquisition involves several major components. For the motion control system you need a mechanical device to move things with the motion controller. For the machine vision system, you need a camera with image acquisition hardware to get images from the camera into your computer. For the data acquisition system, you need a sensor and a data acquisition device. After selecting the components, you then need to take into consideration what software you will use and how the two systems will work together. 6

7 ),! You can group the broad range of machine vision applications into four classes: positioning, detection, measurement, and examination. Positioning applications deal with the alignment or guidance of objects in the image. For instance, you may need to guide a robotic arm along a particular path or detect the location of certain reference objects within the camera s Field of View. Positioning applications help you track the movement of objects in an image. Detection applications determine the presence or absence of an object. Many times, the benefit of using machine vision for this type of application is the speed at which you can process images. For example, suppose the manufacturer of tablet packs wants to ensure that each pack has drug tablets at certain locations. A machine vision system can test these objects hundreds or even thousands of times faster than a human operator. Measurement applications deal with gauging distances, angles, or other quantities through visual inspection. With robust tools like IMAQ Vision from National Instruments, you can calibrate pixels to real-world units like millimeters or inches. Examination applications are those that identify differences among objects in one or more images. Does a cell change its shape over time in a biology experiment? Machine vision can answer a question like this for you. 7

8 ), Grid Inspection!. <: Pick-And-Place!. <:% 3 Velocity Profiling!. <:$, 2 There are several types of motion applications that can be performed with the same basic steps that we ve just outlined. For example, a grid inspection type of motion is very common. With an overhead camera, actuator, or sensor, a stage moves back and forth in a raster scanning motion to cover all points in a grid. For example, this template may be used for filling or sampling test tubes or inspecting pixels under a microscope. Application Example: Micro Arrays A pick-and-place application involves moving from a parts bin to various part targets. At both the bin and the part target, a third axis of motion drops to pick or place a part. In a velocity profiling application, a conveyer is driven in velocity mode under a camera or sensor. As an object passes under the camera, the belt decelerates so the inspection can occur with greater detail. After the object has passed, the belt speeds up again to maximize throughput. 8

9 !. :2, Medication Camera PXI, Motion Controller, and Image Acquisition Board 2 Axis Stage Petri Dishes Motor Drive Servo Valve Using similar methods, the above image shows how you could use a calibrated vision-guided motion system to locate Petri dishes and dispense a treatment to each of them. If these Petri dishes were each filled with different viruses, you could then use the vision system to observe the reactions in each of the dishes. This is a simplification of an automated drug discovery machine. 9

10 $ < : " # $ % & '! ( Configurable environments are often menu driven environments where you can easily go through and configure your system to do what you need it to do. You can think of them as offering pre-written blocks of code that you simply configure to meet your needs. Programmable environments on the other hand, require you to use standard programming languages such as LabVIEW, C, or Visual Basic to accomplish your tasks. Configurable systems offer ease of use, interactive development, and do not require programming ability. However, these types of systems often limit the flexibility and integration with other components in the system. Motion Assistant seeks to bridge the gap by offering all of the features of a configurable system and enabling you to then generate code for the more flexible programmable environments. 10

11 $ < 2 ), ), ) 8/ ) % 01 "! = Similar to configurable and programmable Motion, NI offers the same capabilities for Vision with NI Vision Builder for Automated Inspection and NI Vision Assistant: Configurable environments are often menu driven environments where you can easily go through and configure your system to do what you need it to do. You can think of them as offering pre-written blocks of code that you simply configure to meet your needs. Programmable environments on the other hand, require you to use standard programming languages such as LabVIEW, C, or Visual Basic to accomplish your tasks. Configurable systems offer ease of use, interactive development, and do not require programming ability. However, these types of systems often limit the flexibility and integration with other components in the system. Motion Assistant seeks to bridge the gap by offering all of the features of a configurable system and enabling you to then generate code for the more flexible programmable environments. 11

12 2! 1 12

13 ) $ %, $! 7 ) > ((3 -?!!! A > < * ) %, $ ) B > (. > C (D ' (( ) ' (E >. F B C D ' G ' G H' > ). H / ) (8G G $ Last year NI introduced the Compact Vision System. As explained previously, we are moving the programming and implementation of acquiring data from sensors and analyzing those data closer and closer to the sensor. The reason for that is stability, ruggedness, size, speed. The NI CVS has the following specs. 13

14 ! $" $8 3 2 $ $ $" $" %! So the message is that the code generation allows you to effortlessly move from a configurable environment to a very programmable and flexible environment. 14

15 !. : % 8 I 9 & 8 $ ) " $ $8 $ 8J 7 % E $ % 5! Recipe: PXI Digital Framegrabber LabVIEW and NI IMAQ Vision DVC filter wheel camera Olympus BX61 Microscope and BX-UCB Microscope Controller Unit 15

16 $ E ((> 2 ) ) &! +J 0 $ % 3! $ 9 K 3 & $ $ $L &! 8% * 2, M % % $! 5, %, 4 % 6! 8 $ %,, %, / %, D 2 N B E ( Demos at the NI PittCon 2004 Booth: Sample Handling using LabVIEW and Compact FieldPoint\ Automated ph Measurements with a PC Automated Test Tube Inspection with LabVIEW, NI IMAQ/Vision and Motion Control Connect and Control Your Instrumentation with LabVIEW Automated MALDI-MS Data Acquisition Accurate laser beam Applied Biosystems MDS SCIEX Laboratory Information Management System (LIMS) VI Engineering PDA-based Instrument Control PVI Systems Laboratory Monitoring System (Plexxium) Mack Information Systems 16

17 ) 3 I L 1 = D 2 N B E ( Demos at the NI PittCon 2004 Booth: Sample Handling using LabVIEW and Compact FieldPoint\ Automated ph Measurements with a PC Automated Test Tube Inspection with LabVIEW, NI IMAQ/Vision and Motion Control Connect and Control Your Instrumentation with LabVIEW Automated MALDI-MS Data Acquisition Accurate laser beam Applied Biosystems MDS SCIEX Laboratory Information Management System (LIMS) VI Engineering PDA-based Instrument Control PVI Systems Laboratory Monitoring System (Plexxium) Mack Information Systems 17

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