Dual-Camera Package Inspection Across a Conveyor Gap
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Solution Overview
Problem
Existing quality control stations for packages, particularly carton packages, struggle with inconsistent and unreliable detection of quality issues due to manual assessments and limitations in automatic systems, leading to delayed detection and increased waste.
Innovation Solution
A package quality inspection station utilizing a conveyor system with a belt brake and dual cameras to capture top and bottom images simultaneously or within a short time span, combined with AI/ML models to assess top and bottom features together, incorporating operator feedback for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a single conveyor belt system is used to transport packages, then the device complexity is reduced, but it becomes impossible to capture top and bottom image data simultaneously, leading to delayed quality issue detection
Solution Approach 1:
The conveyor system is divided into multiple independent conveyor belts (first conveyor belt for top surface, second conveyor belt for bottom surface) that can operate independently. This segmentation allows simultaneous capture of top and bottom image data while maintaining manageable complexity through modular design.
Solution Approach 2:
The system transitions from a single-plane conveyor to a multi-plane configuration where packages are conveyed on multiple levels. The first conveyor belt conveys packages on a top plane while the second conveyor belt conveys packages on a bottom plane, enabling simultaneous imaging from both surfaces without increasing temporal complexity.
2Reliability
If top and bottom image data are captured at different times, then the imaging system complexity is reduced, but package deformation between captures leads to unreliable quality assessment
Solution Approach 1:
The imaging system merges top surface imaging and bottom surface imaging into a single synchronized operation. Both cameras capture images simultaneously as packages pass through the imaging zone, ensuring that top and bottom features are assessed in the same temporal context, thereby improving reliability without requiring complex sequential positioning mechanisms.
3Reliability
If manual quality assessment by personnel is used, then the device complexity is minimized, but consistency and reliability of quality detection deteriorate due to human variability
Solution Approach 1:
The system replaces manual visual inspection with an automated optical imaging and image processing system. Cameras capture high-resolution images of package surfaces, and image processing algorithms automatically analyze these images for defects, replacing human personnel with a consistent, repeatable automated assessment process that eliminates human variability.
4Loss of substance
If early detection of quality issues is achieved, then food waste is reduced, but the complexity of the inspection station increases
Solution Approach 1:
The inspection station performs quality assessment early in the packaging process by imaging packages immediately after they are formed and sealed. This preliminary inspection allows defective packages to be identified and removed before they proceed further down the production line, preventing waste of subsequent processing steps and reducing overall food waste.
Data Source
AI summary
A package quality inspection station (100) is provided. The station (100) comprises a first conveyor belt (102) and a second conveyor belt (108) arranged to abut a bottom portion (104) of a package (106). The second conveyor belt (108) is placed at distance (D) from the first conveyor belt (102) such that a gap (110) is formed. A belt brake (112) comprising a first and a second lateral belt arrangement (114, 116) arranged to hold the package (106) is provided to bridge the gap (110) and to hold the package (106) such that a top portion (160) and the bottom portion (104) are made visible when conveyed over the gap (110). A top camera (132) is configured to capture top image data (134) depicting the top portion (160), and a bottom camera (136) configured to capture bottom image data (138) depicting the bottom portion (104). A controller (142) can be configured to receive the top image data (134) and the bottom image data (138) and to identify quality issues linked to the package (106) based on the top image data (134) and the bottom image data (138) in combination.