Automated Vision Inspection for Bottle Crate Filling
Ražošanas un iepakošanas līnijās ir situācijas, kad kastē netiek ievietots pareizs pudeļu skaits vai arī pudeles neatbilst standartiem (piem., nav aizkorķēta). Tas notiek iekārtas mehānisku kļūdu vai neprecīzas padeves dēļ. Lai izvairītos no izdevumiem par pasūtītāja reklamācijām un soda naudām, pietiek uzstādīt vizuālās kontroles risinājumu un nodrošināt, ka ikviens pasūtītājs saņem kvalitatīvu preci.
📌 The Challenge
Ražošanas līnijā tika konstatēti gadījumi, kad visas paredzētās pudeles netika ievietotas kastē. Manuālā pārbaude bija neefektīva. Papildus tika novērti defekti, kad pudeles nav pilnībā aizkorēķētas.
🔧 Complete Solution
Izstrādāta vizuālās pārbaudes sistēma, kas apvieno industriāla līmeņa attēlveidošanu, piemērotu apgaismojumu un precīzu aktivizācijas loģiku. Vienā attēlā tiek pārbaudīta visa kaste, lai noteiktu, vai kastē ir visas nepieciešamās pudeles un katrai pudelei ir korekti uzlikts vāciņš.
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Vision Sensor: Banner iVu Plus TG
At the heart of the system is the iVu Plus TG image sensor — a powerful, self-contained vision sensor with integrated display and processing.
Captures a high-contrast image of the entire crate and runs an onboard inspection algorithm to count bottle caps. If fewer than 20 caps are detected — or if a bottle lacks a cap — it triggers a fail signal in real time.
Key specs:
- 752×480 pixel CMOS sensor
- Up to 60 fps image acquisition
- Built-in 6 mm lens and red LED ring light
- Ethernet, USB, and discrete I/O connectivity
- Integrated touch display or remote Vision Manager software control
- IP67-rated housing for industrial environments
Illumination: Red LED Strip – Banner WLF12 Pro
To ensure consistent and accurate cap detection, we used an industrial-grade LED light strip with focused red output.
Mounted inside a custom-built aluminum light hood, the WLF12 Pro generates high-contrast red illumination that enhances the visibility of cap edges. This ring-like reflection is key to accurate detection by the iVu vision sensor. The enclosed lighting environment also isolates the imaging area from external interference, maintaining consistent image quality.
Key specs:
- Programmable RGB LEDs — configured to emit red illumination for optimal contrast in vision tasks
- Fully sealed design (IP66/IP67/IP69K) — suitable for washdown and damp environments
- Cut-to-length flexibility — customized to match the crate’s inspection zone
- 120° beam angle — delivers wide, even light distribution across the full crate
Triggering Logic: Dual Photoelectric Sensors – Banner S18-2 Series
Two S18-2VPDS-Q8 photoelectric diffuse-mode sensors coordinate crate detection and camera activation.
Sensor 1: Detects crate entry → Activates the LED lighting
Sensor 2: Confirms crate alignment under the camera → Triggers image capture by the iVu sensor
This logic ensures accurate timing adjustments and minimal false triggers — maximizing reliability and minimizing system wear.
Key specs:
- Operating range: up to 300 mm
- Voltage: 10–30 V DC, PNP output
- Bright visible red LED for precise alignment
- IP67-rated cylindrical body (M18)
