Automated Label Inspection via Reference Image Comparison
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Solution Overview
Problem
Current label inspection methods are inefficient and prone to human error, requiring manual visual inspection and complex data processing, which slows down the printing process and increases costs, especially in industries where high accuracy is crucial for regulatory compliance.
Innovation Solution
A product label printing and checking system that uses data processing means to control printing, acquire images of printed labels, and check for defects by comparing them against a reference image using an inspection mask and appropriate tools, allowing for real-time configuration and optimization of inspection tools and parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual visual inspection is used, then inspection accuracy can be maintained at a basic level, but inspection speed is slow and operator errors occur
Solution Approach 1:
The patent replaces manual visual inspection with an automated image processing system that uses digital cameras to capture label images and computer algorithms to analyze defects. This substitution eliminates human operator limitations while maintaining high inspection accuracy through systematic computational analysis.
Solution Approach 2:
The system creates digital copies (images) of physical labels and performs inspection on these copies rather than directly examining the physical labels. This allows repeated analysis, storage of reference images, and automated comparison without handling the actual labels, thereby increasing inspection speed and consistency.
2Productivity
If machine-based visual inspection is used, then inspection speed increases, but system complexity increases
Solution Approach 1:
The inspection system is divided into separate functional modules: image acquisition module, image processing module, defect detection module, and result output module. This segmentation allows each component to be optimized independently and simplifies the overall system architecture while maintaining high inspection speed.
Solution Approach 2:
The system uses a universal image processing framework that can handle multiple label types and defect patterns through configurable algorithms. This multi-functional approach reduces the need for multiple specialized devices, thereby reducing overall system complexity while maintaining high productivity.
3Reliability
If comprehensive label inspection is implemented, then quality control improves, but processing time increases
Solution Approach 1:
The system performs preliminary image acquisition and basic processing steps during the printing process itself, rather than waiting for post-print inspection. Reference images are captured and stored in advance, allowing rapid comparison with printed labels and reducing overall processing time while maintaining comprehensive quality control.
Solution Approach 2:
The inspection process runs continuously alongside the printing process, with images captured in real-time as labels are produced. This continuous inspection eliminates idle time between printing and inspection, ensuring comprehensive quality control without significant processing delays.
4Productivity
If human operators conduct inspection, then flexibility in inspection criteria can be adjusted, but cost increases and productivity decreases
Solution Approach 1:
The inspection system incorporates dynamic adjustment capabilities where inspection criteria and algorithms can be modified based on different label types, defect patterns, and quality requirements. This flexibility is achieved through software configuration rather than physical reconfiguration, maintaining high throughput while providing necessary adaptability.
Data Source
AI summary
A product label printing and checking system, comprising data processing means configured to: control the printing of product labels; control the acquisition and reception of images of the printed labels by an image acquisition device such as an optical scanner; and check the printed labels for defects, wherein each printed label accords with a label format specification for that label, whereby the label has a common layout and comprises printed product-related information located in one or more regions on the label, wherein the data processing means includes a label checking module in which there is provided a reference image of the label, and the checking module is configured so that the acquired images are sequentially compared against the reference image according to pre-determined quality control indicators relating to the expected information content and location in the label regions, and wherein the label is flagged for review or rejection if it is non-compliant. The label format specification may be determined and/or stored before a print run, in the form of an accessible file. This may then be retrieved by the label printing and checking system before a print run using that label format. In an aspect of the invention the label format specification may be used to provide instructions to be sent to a printer for the printing of each label. The reference image and its associated inspection mask may thus be configured in real time by assembling specifications for label region location, region information and inspection tool, and optionally inspection tool parameters.