360° label inspection machine

I. Project Design Basis

1. Project Overview

1.1 Project Name: PET Bottle Label Online Inspection Machine

1.2 Project Description: Utilizing advanced machine vision inspection technology, this system performs fully automatic, non-contact online inspection of PET bottle labels, including the presence and height of labels.

1.3 Rated Output: 60,000 units/hour.

1.4 Bottle Type: PET bottle.

2. Environmental Conditions

2.1 Optimum Altitude: 5-3000 meters above sea level;

2.2 Optimum Ambient Temperature: 5°C-40°C;

2.3 Optimum Ambient Humidity: 50-65% RH;

2.4 Factory Conditions: Parameters such as floor levelness and load-bearing capacity must meet relevant national standards and meet the normal operating requirements of the machine;

2.5 Factory Storage Conditions: After arriving at the factory, parts and machines must be stored in a location that meets relevant national standards.

Note: Lubrication and maintenance must be performed to prevent damage to the surface of parts or deformation that could affect normal installation, commissioning, and operation of the machine.

3. Equipment Operating Conditions

3.1 Noise: ≤85 dB; actual noise levels may vary depending on the container/package being processed, machine power, and building acoustic characteristics.

3.2 Voltage: 220V, 50Hz, single-phase (special voltages require prior notification).

3.3 Total Power: Approximately 1.0kW; Control Voltage: 24VDC.

3.4 Compressed Air: 0.5MPa, air consumption per rejection cycle approximately 0.01L.

II. Equipment Introduction

1. Installation location: on the single row straight conveyor line behind the labeling machine.

2. System Workflow

Figure: System working principle and flow chart

3. System Operation

3.1. When a bottle passes the positioning sensor, its arrival is detected and the control unit records the can ID and the current encoder value.

3.2. The positioning sensor triggers the camera to capture an image of the current bottle label. After acquisition, the image processor processes the image and transmits the processing results to the human-machine interface for dynamic display and to the control unit for the removal of unqualified bottles.

3.3. Upon receiving the unqualified signal, the control unit notifies the rejector to remove the can with the corresponding ID.

4. Image Acquisition Components

4.1 Light Source: Utilizes an LED area light source with a lifespan of up to 50,000 hours. Using foreground illumination, it clearly displays information about the object being measured. In the image, the bottle mouth appears as a continuous bright circular ring. A manual aperture fixed-focus lens is used. Adjust the focus ring to achieve the clearest image on the CCD target surface, and adjust the aperture ring to optimize image brightness.

4.2 Camera: Utilizes an area array CCD analog camera with a resolution of 640 x 480 pixels and an image acquisition speed of up to 60 frames per second.

5. Inspection Content and Accuracy

5.1 Inspection Content

1).No label

2).High label

3).Low label

4).Positive and negative label (wrong label orientation)

5.2 Detection Accuracy

7. Equipment Structure and Components

7.1 This machine consists of various detection units and a human-machine interface (HMI). It is suitable for label inspection on high-speed production lines.

7.2 The detection unit utilizes a stable industrial control computer for processing, interacting with the control unit to transmit detection information.

7.3 The electronic control system utilizes imported programmable controllers, program memory, photoelectric switches, induction switches, and other components, combined with a comprehensive program control and HMI interface, forming an advanced automatic control system.

7.4 A rejection confirmation unit is installed to ensure that all defective products are correctly rejected.

7.5 The power distribution cabinet is equipped with industrial air conditioning to ensure a suitable temperature inside the cabinet and extend its life.

7.6 The compact testing cabinet minimizes the equipment footprint.

7.7 The test operation status and fault conditions are displayed graphically on the human-machine interface.

8. System Advantages

8.1 The image processing system hardware utilizes industry-leading imported components, and the software incorporates specialized image processing algorithms, enabling high-speed, high-precision, and high-reliability inspection tasks.

8.2 Custom programs for various bottle shapes can be built in, enabling one-click bottle shape changes.

8.3 Equipped with a rejection confirmation unit, it monitors online to ensure that defective bottles are correctly rejected, ensuring reliable closed-loop control throughout the inspection process.

8.4 The system's modular design, with ample interfaces and space, allows for significant expansion capabilities.

8.5 The equipment has an extremely low failure rate and is simple and convenient to maintain.