Project Overview

Project Name: Online Bottle Finish Inspection System

This system utilizes advanced machine vision technology to perform automatic, non-contact inspection of bottle finish deformation and defects during the production process.

The equipment is designed to operate at a rated throughput of 48,000 bottles per hour.

Operating Environment

• Recommended Altitude: 5–3000 m above sea level

• Recommended Ambient Temperature: 5°C–40°C

• Recommended Relative Humidity: 50%–65% RH

Factory Requirements

• The workshop floor shall comply with national standards for flatness and load-bearing capacity to ensure reliable and stable equipment operation.

• Upon delivery, all equipment and spare parts shall be stored in designated areas that meet applicable national storage standards.

• During storage, regular lubrication and preventive maintenance shall be performed to avoid surface damage, corrosion, or deformation that could adversely affect installation, commissioning, or normal operation.

Equipment Operating Conditions

• Noise Level: ≤85 dB
  (Actual noise levels may vary depending on container type, packaging configuration, machine power, building acoustics, and other environmental factors.)

Power Requirements

• Main Power Supply: 3 × 380 VAC ±10%, 50 Hz, 3PH+N+PE (to be connected between the customer’s main electrical cabinet and the equipment control cabinet)

• Auxiliary Lighting Supply: 220 VAC, 50 Hz, single-phase

• Control Voltage: 24 VDC

• Total Installed Power: Approximately 1.0 kW

Note: Any special voltage requirements must be confirmed in advance, as they may affect equipment specifications, lead time, and pricing.

Compressed Air Supply

• Air Pressure Requirement: 4–6 bar

• The customer is responsible for providing the pneumatic connection from the plant air supply to the machine.

Equipment Description

4.1 Bottle Finish Inspection System

• Equipment Name: Bottle Finish Inspection System

• Model: MT-PK021

• Quantity: 1 Set

• Production Capacity: 48,000 Bottles/Hour

• Applicable Containers: PET/PE Bottles

• Compatible Production Line Speed: 48,000 Bottles/Hour

• Installation Position: Installed within the blow molding machine, either at the bottle discharge point from the mold or along the conveyor chain.

4.2 System working principle and process

                                                             Figure 4: System working principle and flow chart

System Operating Principle and Process Flow

As bottles travel along the conveyor, they pass through a positioning sensor. Once a bottle is detected, the control unit records the bottle identification information together with the corresponding encoder position signal.

The positioning sensor then triggers the camera to capture an image of the bottle finish. The acquired image is analyzed by the image processing unit, and the inspection results are simultaneously transmitted to the Human-Machine Interface (HMI) for real-time monitoring and to the control unit for reject tracking.

When a defective bottle is identified, the control unit sends a command to the rejection device, which automatically removes the defective bottle from the production line.

4.3 Image Acquisition Components

The system is equipped with an LED area light source with an expected service life of up to 30,000 hours. Using front-light illumination, the bottle finish appears as a continuous bright ring, allowing defects to be clearly highlighted and detected.

A fixed-focus lens with manual aperture adjustment is employed. The focus ring is adjusted to achieve optimal image sharpness on the CCD sensor, while the aperture ring is used to fine-tune image brightness for the best inspection performance.

Camera System

The inspection system uses an area-scan CCD analog camera with a resolution of 640 × 480 pixels and an image acquisition rate of up to 60 frames per second, providing reliable and high-speed image capture for accurate defect detection.

4.4 Bottle mouth detection module:

image processing process

4.5 Test Content and Accuracy:

4.5.1 Test Content

A. Through-hole

B. Internal chip

C. External chip

D. Point chip

E. Deformed bottle neck (oval)

4.5.2 Detection Accuracy