Apparatus and method for centralized indexed inspection and rejection of products

The invention provides a method of and apparatus for inspecting a label applied to a container. The method includes the steps of placing the container on a rotatable platform; rotating the platform; detecting an edge of the label as the container rotates on the rotating platform; stopping rotation of the platform at a predetermined position relative to the position of the detected edge of the label; advancing the container to a label inspection station; viewing the label using a machine vision label inspection system; comparing an image obtained by the machine vision inspection system with established criteria to determine if the label meets predetermined standards for the label; and selectively directing the container to a reject outlet if the label does not match the predetermined standards for the label.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to an apparatus and method for centralized indexed 
inspection and rejection of products and containers; and more 
particularly, for centralized indexed positioning of pharmaceutical 
containers for inspection of labels thereon and rejection of improperly 
labelled containers. 
2. Background of the Invention 
In the pharmaceutical industry, the Food and Drug Administration (FDA) 
requires that pharmaceutical companies perform diligent inspections on all 
packaging labels and outserts. Inspections are also required on some 
product containers. The inspections are required to confirm that a product 
is packaged with the correct labels, outserts, etc. In addition, various 
product volume inspections are done during packaging. 
In the prior art, there are two known ways for inspection. The first 
inspection method is to have two people at each inspection area manually 
visually inspect each container for each requirement, thereby meeting the 
FDA requirement of 200% manual inspection. The second method is to 
automatically perform the inspections. This method uses vision systems 
that perform optical character verification (OCV). Such OCV systems are 
computer based and are composed of cameras, lights and computers. There 
are also readers for bar codes or data matrix codes. These readers 
typically are supplied with decoders. 
For example, one such inspection system has an OCV device for first 
inspecting a web of labels prior to the application of the labels to 
containers. After inspection, all labels, both acceptable and 
unacceptable, are then applied to filled containers, but any containers 
with unacceptable labels are rejected from the line at a later station. 
The inspection system also has a separate rejection station for rejecting 
bad containers. The reject stations are mechanical in nature and are often 
displaced from the actual inspection area. Timing or piece counts are 
relied on to reject improper containers. Such systems are not always 
reliable because when the timing or piece count is not correct, the 
rejection station may reject properly labelled containers and may not 
reject improperly labelled containers. Moreover, the problem is compounded 
because normally there are multiple reject stations on a packaging line, 
each being controlled by one or more inspection stations. 
Therefore, the known method of inspections and rejections using cameras, 
readers, etc. on existing equipment is a totally decentralized system, 
which suffers from some very important disadvantages, including: (1) The 
prior art system is very costly to develop, install, maintain and train 
people to use; (2) The prior art system must be customized to each 
particular application; (3) The prior art system only checks separate 
components, not finished products; (4) In the prior art system, each piece 
of equipment that is modified must be revalidated which is very 
time-consuming and costly to the pharmaceutical manufacturer; (5) The 
prior art system requires longer product changeover times; (6) The prior 
art system requires more parts, which are more prone to breakdown; (7) The 
prior art system does not provide coordinated inspection and rejection; 
(8) The prior art system results in extended production downtime while 
being installed and validated. 
Furthermore, U.S. Pat. No. 3,613,885 teaches another method known in the 
art to perform tests as to whether or not a label is applied to a 
pharmaceutical container, but this system does not allow for any 
determination as to the quality of the label, i.e., whether a correct 
label has been applied. It only determines the presence or absence of a 
label. 
Moreover, in the consumer beverage industry, Menardi et al. (U.S. Pat. No. 
4,919,799) teaches a device for sorting beverage cans 16 having trigger 
indicia 48 and code indicia 28 thereon. As described in Menardi et al., on 
column 10, line 62, through column 11, line 34, the trigger indicia 48 is 
the only indicia provided in a circumferential path 128, is positioned at 
a circumferential location with respect to the code indicia 28, and may 
consist of a dark line on a light background or a light line on a dark 
background. As shown in FIGS. 1-4, the sorting device pneumatically 
retains each beverage can 16 on a spinning head unit 120, continuously 
spins each beverage can 16 with spinning means 44, senses the trigger 
indicia 48 with trigger indicia sensing means 46, actuates an illuminating 
device such as a strobe 51 with a read actuation means 54 for providing 
illuminated code indicia, reads the illuminated code indicia 28 with a 
camera 50 of code indicia reading means 52 for providing a code indicia 
image, compares the code indicia image with a predetermined comparison 
criteria in comparison means 56, and rejects unacceptable beverage cans 
with an object segregation means 58 having a blow-off nozzle 170. In 
particular, as described in Menardi et al., on column 9, lines 35-36, the 
spinning head 120 spins continuously at a predetermined rate during 
operation of the system. The read actuation means 54 responds to a trigger 
signal from the trigger means 46 for actuating the code indicia reading 
means 52 for a short period during the continuous spinning of the beverage 
can 16 at a time when the code indicia 28 is positioned in a readable 
relationship with the camera 50 of the code indicia reading means 52, as 
described in Menardi et al., on column 12, lines 5-27. 
SUMMARY OF THE INVENTION 
The invention provides a centralized indexed apparatus and method for 
positioning containers for inspection and rejection. The apparatus 
includes indexed multi-container positioning means and centralized 
multi-container positioning control means. The indexed multi-container 
positioning means responds to multiple containers, for providing indexed 
multi-container positioning information signals to the centralized 
multi-container positioning control means, and further responsive to 
centralized multi-container positioning control signals from the 
centralized multi-container positioning control means, for providing 
indexed accepted or rejected positioned containers. The centralized 
multi-container positioning control means responds to the indexed 
multi-container positioning information signals from the indexed 
multi-container positioning means, for providing the centralized 
multi-container positioning control signals to the indexed multi-container 
positioning means. 
In one embodiment of the invention, the indexed multi-container positioning 
means is rotatably indexed. Moreover, the centralized multi-container 
positioning control means includes a programmable logic controller (PLC) 
means for providing centralized intelligence to control the positioning of 
multiple containers for inspection. 
The centralized indexed apparatus and method for positioning containers for 
inspection and rejection provides important advantages over the prior art 
systems discussed above, including: (1) It performs inspection on a 
finished product; (2) It maintains positive control of the product at all 
times to assure bad products are rejected; (3) It requires no modification 
or reprogramming of existing production equipment; (4) It enables all 
inspection functions to be tested prior to on-line installation; (5) It 
performs all required inspections in one central location; (6) It enables 
most installation and operational qualification (validation) to be done 
off-line; (7) It allows operator training to be done off-line; and (8) It 
minimizes production downtime for installation, validation, maintenance, 
and personnel training. 
Other objects, aspects and features of the present invention in addition to 
those mentioned above will be pointed out in or will be understood from 
the following detailed description provided in conjunction with the 
accompanying drawings.

DESCRIPTION OF THE BEST MODE OF THE INVENTION 
Centralized Indexed Multi-Container Positioning 
As shown in FIG. 1, the invention provides a centralized indexed apparatus 
for positioning containers for inspection and has an indexed 
multi-container positioning means 2 shown in detail in FIGS. 2-10, and 
centralized multi-container positioning control means that is arranged 
inside a main electrical cabinet 4, and that is generally indicated as 3 
and shown in detail in the circuit diagrams in FIGS. 11-17. 
In the broadest sense of the invention, the indexed multi-container 
positioning means 2 responds to multiple containers generally indicated as 
6 moving along a conveyor belt means generally indicated as 8, for 
providing indexed multi-container positioning information signals to the 
centralized multi-container positioning control means 3 inside the main 
electrical cabinet 4, as will be discussed in detail below. In addition, 
the indexed multi-container positioning means 2 also responds to 
centralized multi-container positioning control signals from the 
centralized multi-container positioning control means 3, as also discussed 
in detail below, for providing indexed accepted or rejected positioned 
containers, which are not shown in FIG. 1. As discussed below, the indexed 
multi-container positioning information signals generally include 
inspection information about the multiply positioned containers being 
inspected, such as inspection information about label indicia, and 
generally indicates whether the multiply positioned containers pass or 
fail various inspections. Furthermore, the centralized multi-container 
positioning means 3 responds to the indexed multi-container positioning 
information signals, for providing the centralized multi-container 
positioning control signals, which control the operation of the indexed 
multi-container positioning means 2. 
In the preferred embodiment of the invention, the indexed multi-container 
positioning means 2 is rotatably indexed for rotatably positioning 
containers for inspection in view of one or more different container 
inspection means, generally indicated as 9. Moreover, the centralized 
multi-container positioning control means 3 arranged inside a main 
electrical cabinet 4 includes a programmable logic controller (PLC) shown 
in detail in FIGS. 11-17, having a microprocessor controller means for 
providing centralized positioning intelligence to operate the apparatus, 
and having a memory means for storing an applications control program for 
operating the indexed multi-container positioning means 2. 
Label Inspection Station 
In one particular embodiment, as shown in FIG. 2, the invention is used in 
a label inspection device generally indicated as 10 for positioning 
pharmaceutical containers 12 to inspect for label indicia on labels 14. 
In FIGS. 2-4, the label inspection device 10 has a conveyor means 8 (FIG. 
1) also generally indicated as 150 in FIGS. 2 and 4 for providing 
containers to and from the indexed multi-container positioning means 2. 
The indexed multi-container positioning means 2 of the label inspection 
device 10 has a rotatable dial plate 22 having eight rotatable platens 20 
arranged therein and being rotatably movable through a plurality of index 
inspection stations generally indicated as 102, 104, 106, 108, etc. The 
label inspection device 10 has inspection means generally indicated as 
200, 202, 204, 206, 208 for viewing various indicia on the label 14 as it 
moves around the indexed multi-container positioning means 2. The scope of 
the invention is not intended to be limited to the type of inspection 
means or the type of inspection. The indexed multi-container positioning 
means 2 also has an adjustable container in-feed loader assembly generally 
indicated as 40 for placing containers 12 on the rotatable dial plate 22, 
and an adjustable rotating escapement assembly generally indicated as 700 
for selectively providing either an accepted container to an accept outlet 
80 or a rejected container to a reject outlet 82, shown in FIG. 2. A 
detailed description of these elements and their operation will follow. 
Conveyor Assembly 150 
FIGS. 5A and 5B show the conveyor assembly 150. FIG. 5A shows a conveyor 
belt means generally indicated as 160 and FIG. 5B shows a Grainger motor 
means generally indicated as 170, both of which are known in the art. 
The conveyor belt 160 includes two sprockets 162, 163, two axles 164, 165, 
a roller chain 166, two rollers 167, 168, and a conveyor belt 169. 
The Grainger motor 170 includes a side motor mount plate 172, a side 
conveyor plate 174, a conveyor chain 176, a conveyor motor mount plate 
178, a motor mount plate 180, a chain adjuster 182, and a bore sprocket 
184. 
The scope of the invention is not intended to be limited by the type of 
conveyor assembly used to provide containers to and from the indexed 
multi-container positioning means 2. 
Adjustable Container In-feed Loader Assembly 
As shown in FIG. 2, the adjustable container in-feed loader assembly 40 has 
a pivotally mounted loading arm 42 having a container in-feed assembly 
including a container nesting pocket 43, a vacuum cup 44, and a container 
blocking flange 46. The container nesting pocket 43 receives the container 
from the conveyor assembly 150, is contoured to the shape of the 
container, and can be manually changed to adapt the adjustable container 
in-feed loader assembly 40 to a different container. The vacuum cup 44 
stops and grips the container 12 moving along the conveyor assembly 150. 
The loading arm 42 is pivotally movable between a container receiving 
position where it receives a container 12 from the conveyor line 26 and a 
container delivering position shown in phantom in FIG. 2 where it delivers 
a container 12 to the indexed multi-container positioning means 2 shown in 
phantom in FIG. 2. The container delivering position is located at and is 
coincident with a first indexed inspection station 100 of the rotating 
dial plate 22. The container blocking flange 46 prevents the advance of 
containers 12 on the conveyor assembly 150 when the loading arm 42 is 
delivering a container 12 to the first indexed inspection station. 
FIG. 2 also shows that the pivotally mounted loader arm 42 has a load arm 
assembly linkage with a female rod end 42a, a link arm 42b, and timing 
adjustment plates 42c, for connecting the pivotally mounted load arm 42 to 
an indexer, motor/reducer, clutch brake means generally shown in phantom 
and indicated as 600 that rotates the indexed multi-container assembly 
means 2. The load arm assembly linkage for driving the adjustable 
container in-feed loader assembly 40 with the indexer, motor/reducer, 
clutch brake means 600 is also shown in phantom in FIG. 2. 
The adjustable container in-feed loader assembly 40 also includes a vacuum 
assembly for providing vacuum from a main vacuum supply 500 in FIG. 9 to 
the vacuum suction cup 44 for holding a container during loading. The 
timing of the suction, and lack thereof, of the vacuum cup 44 is 
controlled by the centralized multi-container positioning control means 3. 
These features are all discussed in more detail with respect to the 
discussion of the escapement assembly 700 in FIGS. 7-8. 
In an alternative embodiment, the container in-feed loader assembly 
includes an adjustable star-shaped rotary in-feed 49, as shown in FIG. 10. 
The adjustable star-shaped rotary in-feed 49 significantly increases the 
throughput of the inspection device compared to the load arm 42. The 
adjustable rotary in-feed 49 is adjustable because it consists of a 
plurality of stackable load plates. The stackability of the load plates is 
similar in design to escapement plates 740, 742, 744 shown in FIG. 7 and 
described in detail below. For example, large containers may require 3 or 
more stackable load plates, while small containers may need only one load 
plate. In effect, the number of plates is determined by the height of the 
containers being inspected. 
Adjustable Rotatably Indexed Multi-container Positioning Means 
The indexed multi-container positioning means 2 is manually adjustable in 
height and rotatably indexed for positioning for inspecting containers 
having different label indicia at one time. It includes the rotating dial 
plate 22 and the indexer, motor/reducer, clutch brake means 600 for 
continuously turning (i.e. indexing) the rotating dial plate 22. The 
indexer, motor/reducer, clutch brake means 600 is known in the art and 
supplied by CAMCO; although the scope of the invention is not intended to 
be limited to only such a motor. As shown, the indexer, motor/reducer, 
clutch brake means 600 also include a Browning pulley 602, a gear box 604, 
idler means 606, a Browning belt 608 and other suitable linkage. 
The indexed multi-container positioning means 2 has the eight indexed 
inspection stations 102, 104, 106, 108, 110, etc. arranged on the rotating 
dial plate 22, each having a rotatable platen 20 in FIG. 2 and indicated 
as 302 in FIG. 3 for rotatably supporting the container during label 
inspection, a bearing cup and a sealed ball bearing generally indicated as 
304, to enable low-friction spinning of the container 12, during the 
initial spinning phase of the inspection to establish orientation. The 
scope of the invention is not intended to be limited to either the number 
of indexed inspection stations 102, 104, 106, 108, etc, on the rotary dial 
plate 22, or the number of indexed inspection stations 102, 104, 106, 108, 
etc, used during the inspection of labels. As shown in FIG. 2, the 
rotating dial plate 22 is driven by the indexer, motor/reducer, clutch 
brake means 600 to move in a fixed pattern of preselected increments so 
that the containers on the indexed inspection stations 102, 104, 106, 108, 
etc, move through a series of predetermined inspections by inspection 
means 202, 204, 206, 208, etc. The containers on the indexed inspection 
stations 102, 104, 106, 108, are held at each inspection means 200, 202, 
204, 206, 208, etc for a predetermined period of time. The rotation 
increments of the rotating dial plate 22 will be dependent on the number 
of inspections desired. For example, if there are four indexed inspection 
stations, then each rotational increment will be a 90 degree turn. In the 
preferred embodiment shown in the drawings, there are eight indexed 
inspection stations (although only seven are used) and thus the rotating 
dial plate 22 will advance (i.e. index) 45 degrees with each rotational 
increment. 
It should be noted that the scope of the invention is not intended to be 
limited to any particular means for advancing or indexing the rotating 
dial plate 22. Embodiments are envisioned using linear conveyor system, or 
other table designs, although such other systems for advancing a container 
12 appear to be less efficient and more costly than the embodiment shown 
and described. 
As shown in FIG. 2, one of the eight indexed inspection stations 102 is an 
indexed spinning inspection station 300, which is best shown in FIG. 3. 
During label inspection, the indexed spinning inspection station 300 spins 
the container 12 on the rotatable platen 20, establishes the orientation 
of the container 12 depending on indicia sensed on the label 14, or other 
data, and stops the container 12 from spinning for subsequent testing. 
Then the rotary dial plate 22 rotates so the container is moved for a 
subsequent inspection of the label 14. The centralized multi-container 
positioning control means 3 provides suitable centralized multi-container 
positioning control signals to effect such rotatably indexed inspections. 
It is important to note that as shown and described, the scope of the 
invention is not intended to be limited to only one indexed spinning 
inspection station 300 like the one shown in FIG. 3. 
Moreover, as shown, the indexed spinning inspection station 300 further 
includes a friction disk 306, a drive disk and a curved drive spring 307, 
a drive disk and an electric clutch 308, a motor mount plate 310, a gear 
box 312 and a servo motor 314 for spinning the rotatable platen 302 in 
FIG. 3, that supports the container 12 during inspection. 
In operation, the indexed spinning inspection station spins the container 
12 to allow the entire label 14 to be viewed. The servo motor 314 with an 
electromagnetic clutch engages the rotatable platen 302. The servo motor 
314 spins either until it has rotated 400 degrees or until it receives a 
signal from a UV sensor generally indicated as 200 in FIG. 2, whichever is 
less. The servo motor 314 stops and the electric clutch is released. It is 
important to note that the invention is not intended to be limited to 
label edge inspection with a UV sensor, because the invention is equally 
applicable to establishing orientation with optical or visual sensing, or 
with no label edge sensing at all in the case of a square container. 
In one embodiment, the centralized multi-container positioning control 
signals from the centralized multi-container positioning control means 3 
include encoder signals that activate the servo motor 314, clutch 
disengage signals that disengage the servo motor 314, and servo motor spin 
signals that spin the servo motor 314 for 400 degrees and stop the motor 
if no signal is received from the UV sensor 200 in FIG. 2. If no signal is 
received from the UV sensor 200, or other container indicia sensing means, 
a bad container signal is sent to a shift register in the centralized 
multi-container positioning control means 3. If the centralized 
multi-container positioning control means 3 receives three consecutive bad 
container signals, then it will cause a cycle stop fault. The scope of the 
invention is not intended to be limited to only these steps of operation. 
The indexed multi-container positioning means 2 also includes a 
corresponding plurality of adjustable container clamping means, one of 
which is generally indicated as 330 in FIGS. 3-4. (See also FIG. 1, which 
shows the plurality of container clamping means above the respective 
containers shown). As shown in FIGS. 3-4, the container clamp 300 includes 
an air cylinder 332 for extending and retracting a holddown device 334 to 
clamp the top 12a of the container 12 to and from an extended position and 
a retracted position. As shown in FIGS. 3-4, the container clamp 300 is in 
the extended position for clamping the container 12. In operation, after 
the container 12 is loaded from the conveyor means 150 to the rotary dial 
plate 22, then the holddown 334 of the container clamp 330 clamps down the 
container. During the inspection of labels of the container, the 
adjustable container clamp 330 extends the holddown device 334 for all 
subsequent testing of various other indicia on the label; however, the 
scope of the invention is not intended to be limited to only such an 
embodiment. If desired, the holddown 334 may also be solenoids or other 
reciprocating mechanisms known in the art. The clamping action of the 
holddown 334 maintains the desired position of each container 12 as the 
rotary dial plate 22 rotates incrementally to the next rotational position 
to perform the next inspection, and provides friction between the 
container and the platen 20 so that the servo motor 314 can spin the 
container. 
As shown in FIG. 4, the indexed multi-container positioning means 2 is 
connected to the vacuum pump 500 shown in FIG. 9 to provide vacuum 
pressure, for example, to the adjustable container in-feed loader assembly 
40, and the escapement assembly 700, discussed below. 
In FIG. 4, the indexed multi-container positioning means 2 also includes a 
valve manifold 350, a rotary coupling 352, eight manual air valves 
generally indicated at 354, a value base means 356 and air cylinder valve 
actuators for actuating one or more of the manual air valves. Each of the 
eight manual air valves 354 corresponds to a respective one of the 
adjustable container clamping means. One of the air cylinder valve 
actuators actuates one adjustable container clamp 300 for extending the 
holddown device 334 to clamp the top 12a of the container 12, and another 
one of the air cylinder valve actuators actuates another one of the 
adjustable container clamping means for releasing the holddown device 334 
to unclamp the top 12a of the container 12 in order to release it from the 
rotary dial plate 22, as discussed below. 
In operation, the clamp air cylinder valve actuator actuates the cylinder 
to shuttle the clamp cylinder valve. When the clamp cylinder valve 
actuator receives a signal from the centralized multi-container inspection 
control 3, this opens up the air to the extend port of the cylinder which 
extends and physically shuttles the valve. 
The adjustable container clamp 300 is manually adjustable for adapting to 
containers having various heights, as follows. The indexed multi-container 
positioning means 2 includes a main column 380 having drill bushings 382, 
a top plate 384 arranged on the main column 380, a top plate clamp 386 
with an aperture, a releasable top plate clamp 388 and a spring plunger 
390. The releasable top plate clamp 388 is inserted through the aperture 
(not shown) and into one of the drill bushings 382 for adjusting the 
height of the indexed multi-container positioning means 2. 
In operation during label inspection, as shown in FIG. 2, the rotary dial 
plate 22 is rotationally incremented for positioning container for 
inspection by the inspection means 200. As discussed above, the indexed 
spinning station 300 in FIG. 3 is used to orient the container 12 and 
label 14 for subsequent inspection. Since the inspection to be performed 
is preferably an inspection of the entire label 14, it is necessary to 
properly position the container 12 so that the label 14 can be viewed by a 
first inspection means such as a machine vision label inspection system 
200. Proper orientation is achieved by identifying a label edge detection 
system and rotationally orienting the container 12 based upon the detected 
label edge. Such a label edge detection system will detect an indexing 
marking on the label 14, such as ink or other optical indicia printed 
along the inner edge of one side of the label 14. Typically, the ink will 
be a fluorescent ink visible in ultraviolet light, or it can be another 
ink, such as a magnetic ink, that is easily detected by appropriate 
detection equipment. As shown in FIG. 3, the servo motor 314 spins the 
container 12, and the inspection means 200 detects the label edge. When 
the label edge is detected, the centralized multi-container control means 
3 will stop the operation of the servo motor 314, and consequently the 
rotation of the platen 20, at a desired position to permit subsequent 
label inspection. It is to be appreciated that the servo motor 314 will 
not necessarily be immediately stopped upon detection of the label edge, 
it may instead be controlled to stop a selected number of degrees of 
rotation after detection of the label edge, for example, 90 or 180 degrees 
after detection of the label edge. The stop location will be dependent on 
the desired position of the container 12 for subsequent inspection. 
Although it would also be possible to apply a detectable indexing marking 
to the container 12 and to detect the container marking, this is a less 
desirable approach as it would require the labels to be applied to the 
containers 12 in a specific relationship to the container indexing marking 
so that the label 14 is properly positioned for inspection when such a 
container indexing marking is detected and platform rotation is stopped. 
This approach would require additional steps in orienting the container 12 
before the label 14 is applied to the container 12, and is thus a less 
preferable approach to orienting the container 12 and label 14 for label 
inspection. 
After inspecting the container 12 at the second indexed inspection station 
102, the rotary dial plate 22 will rotationally advance to a third indexed 
inspection station 104 where label inspection occurs. The label inspection 
uses a second inspection means such as a machine vision inspection system 
202 to view the label 14 affixed to the container 12. The machine vision 
inspection system 202 generates an image that is compared with established 
criteria (such as an image of how the correct label should look) to 
determine if the label 14 meets predetermined standards for the label. If 
the label 14 fails such test, then the centralized multi-container control 
means will generate a reject container signal to the escapement assembly 
700, as shown in FIG. 6, which will cause the container 12 to be sent to 
reject outlet 82. 
The scope of the invention is not intended to be limited to the order of 
inspection. For example, in one embodiment envisioned the orientation step 
of indexed inspection station 102 may be performed after an initial label 
inspection, as described above, in connection with indexed inspection 
station 104, instead of before. In effect, the inspections are reversed. 
The reversal of the order may be appropriate, for example, if there is a 
square container, and it is desired to inspect four sides of the 
container. In such case, the in-feed container load assembly 40 will place 
the container in a position for inspection of two sides of the container, 
after which it will be rotated to permit inspection of the other two sides 
of such containers. 
Further inspections may be provided at a subsequent indexed inspection 
station 106, including, for example: fill level inspection using a visual 
inspection system in transparent or semi-transparent containers; cap seal 
inspection using a pressure test (which may also be performed before the 
container is placed on the rotary dial plate, as discussed below); bar 
code inspection using a vision system and/or laser reader system; metal 
contaminants inspection using a magnetic inspection system; and weight 
inspection. The number of specific inspections to be employed will depend 
on the specific product in the containers. Depending on the number of 
desired inspections, there may be fewer or more platforms and stations. In 
such an embodiment, after all the inspections are completed, then the 
centralized multi-container control means 3 will generate a reject message 
if the container 12 fails any of the tests, which will cause the 
escapement assembly 700 to send the container 12 to the reject outlet 82. 
It is to be appreciated that the inspection functions may be implemented at 
separate stations as described above, or that more than one function can 
occur at any one station. However, for convenience of servicing and to 
obtain a higher throughput, a single inspection function per station is 
preferred. 
Adjustable Rotating Escapement Assembly 
As shown in FIGS. 2, 4 and 6, the adjustable rotating escapement assembly 
700 takes containers from the indexed escapement station 108 and provides 
them either back to the conveyor 150 at a conveyor position 72 or to a 
rejection outlet 82. The adjustable rotating escapement assembly 700 is 
shown in FIG. 2, and shown in greater detail in FIGS. 7-8. 
As shown in FIG. 7, the adjustable rotating escapement assembly 700 is 
manually adjustable depending on the size of the container, and includes 
one or more stackable escapement plates 740, 742, 744 arranged on a 
central axis 701 for adjusting the height thereof depending on the height 
of the container being inspected. The stackable escapement plates 740, 
742, 744 each have a vacuum pin 746 and an O-ring 748. A roll pin 750 and 
a vacuum hose fitting 752 are also shown. 
As shown in FIG. 8, each of the stackable escapement plates 740, 742, 7844 
is star shaped, has three escapement arms 702, 704 and 706, and has a 
vacuum assembly means for providing vacuum to each escapement arm 702, 704 
and 706 that includes suction cups 708, vacuum cup mounts 710, vacuum 
check valves 712, barbed hose fitting 714, tubing 716, swivel elbow barbed 
hose fitting 718 and drive pins 720. The stackable escapement plates 740, 
742, 744 are very similar in design to the plates of the adjustable rotary 
in-feed assembly 49 shown in FIG. 10 and very similar in design with 
respect to the vacuum means assembly used thereon. 
As shown in FIG. 4, the adjustable rotating escapement assembly 700 has a 
Browning pulley 760 and a Browning belt 762 for connection to a Browning 
pulley 764, which is itself connected by linkage to the indexer, 
motor/reducer, clutch brake means 600. The adjustable rotating escapement 
assembly 700 also includes an escapement shaft 610, an escape vacuum 
supply manifold 612, idler arm means 614, an idler bracket 616, a gearbox 
mount bracket 618. 
The adjustable rotating escapement assembly 700 also includes an escapement 
gate air cylinder mount 770, an air cylinder and rod clevis means 772, a 
rejection gate shaft 774, ball bearing means 776, a mechanically 
controlling rejection gate 778. 
In operation, the escapement assembly 700 is rotated about in preselected 
increments so that the escapement plate arms 702, 704, 706 move through a 
series of at least three predetermined removal positions indicated as 70, 
72 and 74 in FIG. 2. At the removal position 70, an escapement plate arm 
picks up a container 12 from the indexed escapement station 108. If there 
is no reject message associated with the container 12, the escapement 
plate arm will be advanced to a first removal position 72 where it 
releases the container 12 at the accept outlet 80. The container 12 will 
then continue down the conveyor assembly 150 to be packaged for shipment. 
If there is a reject message associated with the container 12, the 
escapement plate arm will advance past the first removal position 72 to a 
second removal position 74 where it releases the container 12 at reject 
the outlet 82, where it will be sent down a chute for disposal. 
The in-feed container load assembly 40 and the escapement assembly 700 are 
synchronously driven by the indexer, motor/reducer, clutch brake means 600 
which drives the rotary dial plate 22. The operations of the transfer 
apparatus 40 and outlet transport apparatus are synchronized to the 
rotation of the rotary dial plate 22. This assures that the rotatable 
platens 20 of the rotary dial plate 22 will always be in position to 
receive or discharge a container 12 when the in-feed container load 
assembly 40 or the escapement assembly 700 is delivering or removing a 
container 12 from either such position. 
The purpose of the reject gate 778 is to act as a secondary assurance that 
failed containers do not proceed further down the line. The rejection gate 
778 has a normal position and an open position, as shown. When the 
centralized multi-container positioning control means 3 sends a signal for 
a good container, the rejection gate 778 opens allowing the container to 
proceed down the line. If a reject signal is received, the reject gate 778 
remains closed, as shown. It is only allowed to open after a reject 
verification is received by the centralized multi-container inspection 
means 3 from the reject verify eye (not shown). In the inspection device, 
upon the unloading of a failed container, when a reject verification 
confirmation signal is sent back to the centralized multi-container 
control means 3, then the reject gate 778 is allowed to open. 
The invention is not intended to be limited to the exact embodiment of the 
in-feed container load assembly 40 and the escapement assembly 700 
described herein. For example, the in-feed container load assembly 40 and 
the escapement assembly 700 could be altered and still remain within the 
scope of the invention. For example, either or both the in-feed container 
load assembly 40 and the escapement assembly 700 could have either a 
pivoting arm structure as described above for the in-feed container load 
assembly 40, or either or both could have a rotating arm structure which 
is similar to that described for the escapement assembly 700. Other 
devices for transfer of containers 12 such as compressed air jets, 
swinging arms, and starwheels could also be used. It would also be 
possible to provide sufficient stations to the rotary dial plate 22 and 
appropriate logic controls such that: a container 12 to be rejected is 
removed directly from the rotary dial plate 22 at a reject station and 
sent to a reject chute; and an accepted container 12 would be removed from 
the rotary dial plate 22 at another, preferably subsequent, accept 
station, and returned to the conveyor line 150 for shipping. 
Inspection Means 
In the embodiment shown and described, the apparatus includes one or more 
inspection means 200, 202, 204, 206, 208, etc. for reading various indicia 
on a label affixed to the container. The inspection means 200, 202, 204, 
206, 208, etc. are commercially available by many different suppliers, 
including Allan-Bradley. The inspection means 200 is used to establish the 
orientation of the container, as discussed in detail above. In general, 
the inspection means 202, 204, 206, 208, etc. inspect the container for 
various indicia and provide a pass or fail signal back to the centralized 
multi-container control means 3. 
In particular, as discussed above, the first inspection means 200 is a UV 
light sensor or other sensing means for detecting the presence or absence 
of a UV coated label 14 to orient the container, and the second inspection 
means 204 is a camera, for example, for reading a lot and expiration 
indicia on the label 14. A third inspection means may include a second 
camera for reading RM indicia on the label 14. 
The inspection apparatus may be supplied by and are the responsibility of 
the purchaser of the inspection apparatus. The purpose of the inspection 
means 200, 202, 204, 206, 208, etc. is to inspect areas of the container 
or label to assure the correct markings are on the product. As containers 
are presented in each station, cameras determine whether the markings on 
the containers pass a comparison test. The line controls include cameras 
and lighting signals that can be enabled through the centralized 
multi-container positioning control means 3. 
In the embodiment shown and described, the purpose of the UV sensor 200 or 
other sensing means is to detect the label edge on a container and to 
control the servo motor 314, so label positioning can occur. The UV sensor 
200 is positioned in front of the indexed spin station 102. As the 
container spins, it looks for the UV coating on the label of the 
container. When it detects a change of UV from high to low, the inspection 
information signal is sent to the centralized multi-container acceptance 
or rejection means. The UV sensor is being activated by the centralized 
multi-container acceptance or rejection means, and becomes active when the 
container is rotatably indexed into the station. It becomes inactive upon 
initiation of the table index. 
The inspection means 200, 202, 204, 206, 208, etc. are adjustably arranged 
on brackets 200a, 202a, 204a, 206a, 208a. When the apparatus is changed 
over to inspect other types of indicia on perhaps other types of 
containers, the inspection device operator must adjust the relative 
position of the inspection means 200, 202, 204, 206, 208, etc. on the 
brackets 200a, 202a, 204a, 206a, 208a to the location of the indicia 
information positioned on the label using the video camera means, 
discussed below. 
Video Monitor Display 
As shown in FIG. 1, the inspection apparatus may include a video monitor 5 
for displaying indicia being viewed on the label by any one of the 
plurality of inspection means for adjusting the same. 
Control Panel 
As shown in FIG. 1, the inspection apparatus includes a control panel for 
operating the container inspection apparatus. The control panel includes a 
main power on/off switch for turning on/off the container inspection 
apparatus, a start button for starting the container inspection apparatus, 
a stop button for stopping the container inspection apparatus, a conveyor 
on/off button for starting and stopping a conveyor means providing the 
containers for inspection, a vacuum generator on/off button for starting 
and stopping a vacuum generator for providing vacuum, a machine jog button 
for providing a jog mode, an emergency stop button for turning off the 
container inspection apparatus in an emergency, an alarm buzzer to 
indicate an alarm, an alarm acknowledgement button for muting the alarm 
buzzer, and a reset button for resetting the container inspection 
apparatus to clear faults. 
Low Level Sensor 
The apparatus may also include a low level proximity sensor 41a in FIG. 2 
for determining if an adequate queue of containers is being fed to the 
container inspection apparatus. 
The purpose of the low level sensor 41a is to determine if an adequate 
queue on the in-feed conveyor is present to assist in the nesting of 
containers into the load arm. When the proximity sensor 41a senses a 
container for a preset time, it is assumed that the queue of containers 
has reached this point. If the eye stays unblocked for a preset time, the 
queue has gone below the minimum level. 
Cap Presence Sensor 
The apparatus may also include a cap presence sensor 41b as shown in FIG. 2 
to assure that a container is entering the indexed multi-container 
positioning means 2. 
The purpose of the cap presence sensor 41b is to assure that a container 
entering the rotating dial plate 22 has a cap 12a. A convergence eye scans 
the container top to confirm the presence of the cap 12a. A signal is sent 
to the centralized multi-container inspection control 2. If no cap 12a is 
detected, the inspection device machine will go into cycle stop, and the 
containers must be manually removed and the machine reset. The operator 
interface includes manually removing an uncapped container and resetting 
the unit, and adjusting a convergence eye height for differing container 
heights. 
Resection Verification 
The apparatus may also include a reject verification means to confirm that 
a rejected container was actually rejected. The reject verification means 
includes a reject verification eye 90 in FIG. 2 positioned to confirm that 
a container, which is supposed to be rejected, was actually rejected. For 
example, a photo reflective eye 90 can be mounted on the reject chute 82 
in position to detect a container as it is rejected. When the photo 
reflective eye 90 is broken by a rejected container, rejection is 
confirmed. Upon a reject signal from the centralized multi-container 
control means 2 if the eye is not broken before the next index, the 
inspection device will go into a cycle stop fault and the reject gate will 
not be allowed to open. The photo reflective eye 90 must be manually 
broken before the fault can be cleared. The operator interface includes 
removing the failed container from the reject gate 778 and break eye beam 
when a fault occurs. The fault can then be cleared by the reset button. 
Centralized Multi-Container Positioning Control 
The centralized multi-container positioning control means 3 includes a 
Programmable Logic Control means, including a Programmable Logic 
Controller generally indicated as 900 and shown in FIG. 11, and I/O PLC 
circuits 910 shown in FIGS. 12-17. 
FIG. 11 shows the architecture for the Programmable Logic Controller 900, 
which can be a standard computer having a central processing unit 902, a 
read only memory 904 (i.e. either ROM or EPROM), a random access memory 
906 (RAM), a data, address and control bus 908, an I/O bus 908a, and an 
input/out circuits 918. The read only memory 904 (i.e. either ROM or 
EPROM) stores a control application program, which is run on the central 
processing unit 902, for driving the I/O PLC circuits 910 shown in FIGS. 
12-17 that are specifically designed for operating the indexed 
multi-container positioning means 2. The central processing unit 902 
provides output control signals on the I/O bus 908a for controlling the 
PLC I/O control circuits 910 shown in FIGS. 12-17. In addition, the 
central processing unit 902 receives input control signals on the I/O bus 
from the PLC I/O control circuits 910 shown in FIGS. 12-17. The scope of 
the invention is not intended to be limited to the specific PLC I/O 
control circuits shown in FIGS. 12-17. 
In one embodiment, the Programmable Logic Controller 900 has a control 
program which drives the specific PLC I/O control circuits 910 shown in 
FIGS. 12-17 causing the inspection device to operate, as follows: 
1. Containers are fed from the conveyor belt assembly 150 onto the in-feed 
loader arm assembly 40 of the station conveyor where a queue is allowed to 
develop. 
2. A proximity sensor and a convergency sensor 41 can be used to monitor 
container queue and height to detect the length of the queue and 
containers without caps. If a missing cap condition is detected, the 
inspection machine shuts down until the condition is cleared, and the 
machine is manually reset by an operator. 
3. The forward movement of the first container 12 in the queue is stopped 
by the load arm 42 where it nestles into a container nesting pocket 43 
thereof. 
4. A bar code reader (not shown) may be activated to scan the bar code on 
the outsert on the top 12a of the container 12. A signal would be sent to 
the shift register. 
5. The load arm 42 indexes and the container 12 moves into a 1st position 
on rotary dial plate 22. The back 46 of load arm 42 moves across conveyor 
assembly 150 to hold back the container queue. 
6. A hold down cylinder 332 in position 1 extends a holddown 334 to place 
pressure on the container cap 12a. 
7. Vacuum from the cup 44 on the load arm 42 releases. 
8. The rotary dial plate 22 indexes to next position. The load arm 42 moves 
back to accept the next container. 
9. An electric clutch on the servo motor 314 engages, and the servo motor 
ramps up to speed thereby spinning the container 12. 
10. An ultraviolet sensor 200 or other optical means monitors the container 
12 for the presence or absence of an ultraviolet coated label 14. The 
container 12 spins until the U.V. sensor 200 detects going from high 
(presence of U.V. coating) to low (absence of U.V. coating), indicating 
the trailing edge of the label and sends a signal to the servo motor 314. 
11. The servo motor 314 stops when it receives the signal from the U.V. 
sensor 200. 
12. The electric clutch releases. 
13. The rotary dial plate 22 indexes to a next position. 
14. A camera 1 searches for correct Lot and Expiration # and sends a 
pass/fail signal to the shift register. 
15. The rotary dial plate 22 is indexed to a next indexed position. 
16. A camera 2 searches for RM# and sends a pass/fail signal to the shift 
register. 
17. The rotary dial plate 22 is indexed to a next indexed position. 
18. The next indexed inspection station is a spare station, as shown in 
FIGS. 2, 4 and 6. 
19. The rotary dial plate 22 is indexed to a next indexed position. 
20. A camera searches for label and cap skew and sends a pass/fail signal 
to the shift register. 
21. The rotary dial plate 22 is indexed to a next indexed position, which 
is an unload position. 
22. The holddown 334 of the cylinder 330 retracts. 
23. The unload star escapement plate 700 continues into position, 
contacting the container 12. Vacuum cups 708 are activated upon sensing a 
container 12. 
24. The rotary dial plate 22 is indexed to a next empty position. The 
unload arm is indexed to the eject position. The safety gate on the 
outfeed conveyor moves across the conveyor assembly 150 if any inspection 
on that container 12 has failed. 
25. If the container inspections have all passed, vacuum is released on the 
unload arm, and the container is free to proceed along the outfeed 
conveyor. Vacuum is released by means of a solenoid activated cylinder cam 
which moves into position to trip a microswitch controlling the vacuum. 
26. The rotary dial plate 22 is indexed to a next load position. The unload 
arm indexes to the reject position. Vacuum is released by means of a 
microswitch activated by a mechanical fixed location cam. 
27. If any inspections on that container have failed, the container will be 
in the reject position. Vacuum is released on the unload arm, and the 
container falls free of the arm. 
28. The reject verification eye 90 in FIG. 2 confirms that the part was 
rejected and sends a signal to the centralized multi-container positioning 
control means 3. 
29. Upon receiving the reject verification signal, the rejection gate 778 
(FIG. 6) is opened. If no reject verification signal is received, the 
rejection gate will remain closed and a cycle stop condition will occur 
with applicable faults. 
The present invention improves over the prior art by providing a direct and 
positive control of the quality of the inspected goods. This is achieved 
by having the inspection function and the removal of the container from 
the line occur during the same operation. It eliminates problems of prior 
art label inspections where the label is inspected prior to application, 
but the label and the container 12 to which it is applied are not removed 
from the line until later in the manufacturing process. It also provides a 
unique approach to inspection of filled containers. 
As those skilled in the art will recognize, the invention is not 
necessarily limited to the specific embodiments described herein, and the 
inventive concept may be implemented in additional ways, all in accordance 
with the claims below.