Empty bottle visual inspection machine

1. Project Overview

1.1 Project Name: Online Bottle Finish Inspection Machine

The system leverages advanced machine vision technology to carry out fully automated, non-contact, online inspection of glass bottle finishes, detecting deformation and breakage with high precision.

The machine has a rated capacity of 48,000 bottles per hour.

Environmental Conditions

• Operating Altitude: 5–3000 meters above sea level

• Ambient Temperature: 5°C – 40°C

• Relative Humidity: 50% – 65% RH

• Factory Requirements: Floor levelness, load-bearing capacity, and other conditions must comply with national standards to ensure reliable operation of the equipment.

• Storage Requirements: After delivery, all parts and equipment must be stored in facilities that meet national standards. During storage, appropriate lubrication and maintenance should be performed to prevent surface damage, corrosion, or deformation that could interfere with installation, commissioning, or normal operation.

Equipment Operating Conditions

• Noise Level: ≤85 dB; actual noise may vary depending on the type of container/package, machine power, building acoustics, and other environmental factors.

• Power Connection: From the customer’s main electrical cabinet to the equipment cabinet.

• Main Power Supply: 3 × 380 VAC ±10%, 50 Hz, 3 PH + N + PE.

• Lighting Power: 220 V, 50 Hz, single-phase.
  (For non-standard voltages, prior confirmation is required, as this may affect equipment specifications, delivery time, and cost.)

• Total Power Consumption: Approx. 1.0 kW.

• Control Voltage: 24 VDC.

• Compressed Air Requirement: 4–6 bar (customer is responsible for providing the air pipeline connection from the air source to the equipment).

Equipment Overview

4.1 Bottle Finish Inspection Machine

• Equipment Name: Bottle Finish Inspection Machine

• Model: MT-PK021

• Quantity: One (1) set

• Rated Speed: 48,000 bottles per hour

• Applicable Containers: PET and PE bottles

• Compatible Production Line: 48,000 bottles/hour PET/PE bottle packaging line

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

4.2 System working principle and process

Figure 4: System working principle and flow chart

System Operating Principle and Process

1. As a bottle passes the positioning sensor, the sensor detects its presence and the control unit records the corresponding bottle ID along with the current encoder value.

2. The positioning sensor then activates the camera to capture an image of the bottle mouth. Once the image is acquired, the image processor analyzes it and transmits the results to the human–machine interface (HMI) for real-time display, as well as to the control unit to prepare for rejection of bottles with defective mouths.

3. When a defect is identified, the control unit signals the rejector to remove the bottle associated with the recorded ID.

4.3 Image Acquisition Components

• Light Source: An LED area light source with a service life of up to 30,000 hours is used. By applying foreground illumination, it ensures that details of the inspection target are clearly visible. On the captured image, the bottle mouth appears as a continuous bright ring. A fixed-focus lens with manual aperture adjustment is employed; the focus ring is adjusted to optimize sharpness on the CCD sensor, while the aperture ring is adjusted to fine-tune image brightness.

• Camera: An area-array CCD analog camera is utilized, providing a resolution of 640 × 480 pixels with an image capture rate of up to 60 frames per second.

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