Shrink wrap product sleeve is placed onto the bottle before entering into a steam tunnel. Occasionally the shrink wrap label is not in the correct position or gets snagged. This causes an unaesthetic package that is not suitable for retail. Each bottle must be manually inspected prior to filling. Shrink wrap colors are anything across the rainbow and many shades in between, including shades of white placed on a white bottle.
The bottle is side belt transfered to an exit conveyor and the bottle is inspected with a GigE camera. Using a combination of UV and white LED lighting, along with a specialty cut filter, the UV lighting causes a blue shift in the color of the product sleeve, while the color of the white bottle appear to be grey. Due to the reliability with traditional color segmentation working with greys, an in-house custom color segmentation routine was used to segment the exposed bottom of bottle that is not covered by the product sleeve. This allowed bottle to be profiled and measured, allowing for a quantitative pass/fail decision.
When customers are finished with a laser ink cartridge, they often send it back using the return box provided with new cartridges. These cartridges are returned to centralized recycling centers across the country by the truck loads. Used cartridges are removed from their packaging and thrown onto a conveyor belt for manual sorting. As volumes steadily increase, addtional manpower is required to aid in the sorting. Since the recycling center is credited for each cartridge processed and certain cartridges have higher number of recyclable components then others, accurate count of models is highly desired.
PC-based vision system monitors the conveyor for cartridges as they enter into the field of view, at which point it makes note of the cartridges encoder location and its orientation. Using a blob tool, the system pre-classifies cartridges based on their shape using a high-end multi-core processsor for parallelized pattern matching. Subsequent secondary pattern matching is performed in some instances to identify other key markers when subcategorization is required. A local register retains counts of each cartridge identified. Encoder location, orientation, and cartridge ID are passed to a spider robot to pick and place the cartridges into large bins. Multiple instances and orientations of well over one hundred cartridges were trained into the system.
QR code and human readable text on the trading card would occasionally not match. Updated the user configuration and faulty remote software.
Deployed in less than two weeks with surplus stock, using 4VT’s standard framework and a VisionPro Quickbuild script. Cards were fed onto a vacuum belt, triggered by a photoeye, and if there was not a match, system would blow the product off at the air gap between the vacuum belt and the accumulator belts at a rate of 10 cards per second.
Existing smart sensor does not have the tools to determine if label placement is out of spec. Quality Department requests ability to make sure that the Lot/Date code is present.
Line was moved from another facility to a local one and no documentation could be found. The existing controls system was reverse engineered, and the vision camera upgraded to a Cognex InSight that mimicked the old system. Retrofit required removal of some of the existing material handling components, which were removed, modified, and installed over a long weekend. System was successfully brought online for the start of production.
After the nail polish bottle has been capped, a consumer label is applied to the top of the cap that indicates the color name and product number. Space constraints prevents an inspection camera to be placed after the label applicator, so the Vision System needs to be able to compensate for 360 orientation of the label.
With some blob morphology techniques the orientation of the text can be determined. Afterwards an OCR tool was applied to read the text twice, oriented 180 degrees apart. If the text found did not match the HMI, the product was rejected.