Filled Bottle Inspection Machine

1. Project Overview

1.1 Project Name: Online Glass Bottle Finish Inspection System

This system adopts state-of-the-art machine vision technology to achieve fully automated, non-contact, online inspection of glass bottle finishes. It effectively detects defects such as deformation and breakage at the bottle mouth, ensuring product quality and production efficiency.

Rated Capacity: Up to 48,000 bottles per hour

2. Environmental Requirements

• Altitude Range: Suitable for installation at elevations between 5 and 3000 meters above sea level.

• Operating Temperature: Designed for use in environments ranging from 5°C to 40°C.

• Relative Humidity: Optimal performance at 50%–65% RH.

• Factory Conditions: The workshop must comply with national standards for floor levelness and load-bearing capacity to ensure stable and reliable machine operation.

• Storage Conditions: Upon delivery, equipment and components should be stored in facilities that meet national standards. During storage, proper lubrication and maintenance are required to prevent surface damage or deformation that may impact installation, commissioning, or operation.

Equipment Operating Conditions

• Noise Level: ≤85 dB. Actual noise values may differ depending on container type, package specifications, machine power, and acoustic properties of the building.

• Power Supply: Connection between the customer’s main electrical cabinet and the equipment cabinet.

• Main Power: 3 × 380V AC ±10%, 50 Hz, 3PH + N + PE

• Lighting Power: 220V, 50 Hz, single-phase

• Note: Special voltage requirements must be communicated in advance; equipment specifications, delivery time, and pricing may vary accordingly.

• Total Power Consumption: Approx. 1.0 kW

• Control Voltage: 24 VDC

• Compressed Air: 4–6 bar (air piping connection from the customer’s air source to the main unit of the equipment is required).

Equipment Overview

Bottle Finish Inspection Machine

• Model: MT-PK021

• Quantity: 1 set

• Production Capacity: 48,000 bottles/hour

• Compatible Containers: PET and PE bottles

• Applicable Production Line: High-speed lines rated at 48,000 bottles/hour

• Installation Position: Integrated within the blow molding machine—either at the bottle exit point of the mold or along the conveyor chain, depending on site layout.

4.2 System working principle and process

Figure 4: System working principle and flow chart

System Operating Principle and Workflow

1. Bottle Detection:
   As a bottle passes the positioning sensor, its presence is detected. The control unit then records the bottle ID along with the current encoder value.

2. Image Capture and Processing:
   The positioning sensor triggers the camera to capture an image of the bottle finish. The image is then analyzed by the image processor, and the results are transmitted to both the human–machine interface for real-time display and to the control unit, which prepares for possible rejection of defective bottles.

3. Defect Rejection:
   If the analysis identifies a defect, the control unit sends a signal to the rejection system, which removes the corresponding bottle from the production line.

4.3 Image Acquisition Components

• Light Source:
  An LED area light source with a service life of up to 30,000 hours provides foreground illumination, ensuring clear visualization of the inspection area. Under this setup, the bottle finish is displayed as a continuous bright ring in the captured image. A manual-aperture fixed-focus lens is used; the focus ring is adjusted to maximize clarity on the CCD sensor, while the aperture ring is fine-tuned to optimize image brightness.

• Camera:
  The system employs an area-array CCD analog camera with a resolution of 640 × 480 pixels, capable of acquiring images at speeds 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