Mass Packaging Line Vision for Crowded Object Defect Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional computer vision systems for manufacturing lines are inflexible, sensitive to environmental conditions, limited in detection capability, and struggle with object crowding, leading to inefficiencies and high implementation costs.
Innovation Solution
A modular computer vision system using a machine learning model that can identify objects of different colors, sizes, and configurations, with ultraviolet lighting and imaging devices, and a relay system to transmit compact analog data for efficient defect detection and line operation adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional computer vision systems are used for manufacturing lines, then defect detection capability is provided, but the systems are inflexible and sensitive to environmental conditions leading to high implementation costs
Solution Approach 1:
The system is divided into modular components: enclosure module, lighting module with UV LEDs, imaging module with cameras, and processing module. Each module can be independently configured and replaced, enabling flexibility while maintaining manageable complexity through standardized interfaces and functions.
2Measurement precision
If conventional imaging systems are used without UV lighting, then standard visible light detection is achieved, but detection capability for certain defects is limited
Solution Approach 1:
The system employs UV lighting (wavelength parameter change) to illuminate objects, causing fluorescent materials to emit visible light. This parameter change in illumination wavelength enables detection of defects that are invisible under standard visible light, improving measurement precision without excessive energy consumption.
3Productivity
If objects are conveyed in non-single-file configurations, then productivity is improved, but object crowding makes defect detection more difficult
Solution Approach 1:
The system transitions from single-file to multi-row conveyor configurations, adding spatial dimensionality to object conveyance. Multiple cameras positioned at different angles capture images of crowded objects, and image processing algorithms separate and analyze individual objects even when closely spaced, maintaining defect detection capability while improving productivity.
4Measurement precision
If UV lighting is used to illuminate objects, then fluorescent coatings become visible for detection, but visible light interference must be blocked
Solution Approach 1:
The enclosure is designed with selective light transmission properties: UV-transparent windows allow UV illumination to reach objects and fluorescent emissions to reach cameras, while visible light-blocking materials prevent ambient visible light interference. This local quality differentiation in the enclosure enables precise coating detection without complex active lighting control systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible and efficient detection of defects in objects conveyed en masse, reducing false positives, and enabling timely responses to production line issues without requiring extensive modifications.
Implementation Method 1
arranging at least one ultraviolet light with the enclosure; capturing image data using the imaging device while the objects pass through the enclosure on the mass packaging line and the ultraviolet light shines ultraviolet light onto the objects
Data Source
AI summary
A monitoring system for mass packaging lines. In an aspect, a method includes creating image data by imaging objects on the mass packaging line using an imaging device while the objects are exposed to a light and using a processor having memory associated therewith to process the image data to determine a characteristic of at least one of the objects. The objects are conveyed on the mass packaging line in a configuration other than a single file.