Packaging Box Placement Detection Using One Machine Vision System
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Solution Overview
Problem
Current automated packaging production lines rely on manual visual inspection and require multiple machine vision systems to ensure materials like swabs and certificates are present, leading to high costs, large space occupation, and reduced efficiency due to the need for template adaptations with minor design changes.
Innovation Solution
A method using a single machine vision system with image processing techniques to determine material placement by calculating variance in grayscale values, reducing hardware costs and space, and allowing real-time parameter adjustments for product adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two separate machine vision systems are used to detect both certificate and swab presence, then detection accuracy is improved, but hardware cost and device complexity significantly increase
Solution Approach 1:
The patent merges the detection functions for certificates and swabs into a single machine vision system. The system captures images of the packaging box interior and uses image processing to detect both certificate presence (via circular pattern recognition) and swab presence (via reflection detection) simultaneously, eliminating the need for two separate systems while maintaining detection accuracy
Solution Approach 2:
The single machine vision system is designed to perform multiple detection functions: detecting certificate presence through template matching of circular patterns, detecting swab presence through reflection analysis, and determining material placement orientation. This multi-functional approach replaces multiple specialized systems with one universal detector
2Measurement precision
If two machine vision systems are deployed, then detection capability is enhanced, but the apparatus occupies larger space
Solution Approach 1:
By combining certificate detection and swab detection into one machine vision system, the patent reduces the spatial footprint. Instead of requiring two separate cameras and processing units occupying different spaces, a single integrated system performs all detections within one compact apparatus configuration
3Measurement precision
If template matching is used for certificate detection, then detection accuracy is improved, but production efficiency decreases when design changes occur requiring new templates
Solution Approach 1:
The patent employs reflection-based detection for swabs and simplified pattern recognition for certificates that focuses on key geometric features (circles, rectangles) rather than detailed template matching. This approach allows the system to adapt to design variations by adjusting detection parameters like reflection thresholds or geometric feature dimensions, rather than requiring complete template replacements
4Adaptability or versatility
If manual visual inspection is used, then flexibility in handling design changes is maintained, but productivity decreases due to eye fatigue and missed inspections
Solution Approach 1:
The patent replaces manual visual inspection with an automated machine vision system that uses image capture and digital processing. The system automatically detects certificates through circular pattern recognition and swabs through reflection analysis, eliminating human eye fatigue while maintaining adaptability through programmable detection algorithms that can be adjusted for different designs
Data Source
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AI summary
The present invention provides a method for detecting the material placement condition in a packaging box, including an original image acquisition step, an image reduction step, an image enlargement step, an image processing step and a confirmation step, etc. By reducing and enlarging the original image, it can quickly determine the placement condition of the relevant materials in the packaging box, realize the high degree of automation of the packaging production line, and eliminate missed inspection due to manual visual inspection..