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1 Introduction
With the improvement of people's living standards, the market demand for beverages is also increasing, and the quality of products has become a concern for manufacturers and consumers. The appearance of the beverage bottle directly or indirectly affects the quality of the beverage inside, so in order to reduce the number of defective products, it is necessary to increase the detection process. Manual visual inspection and product marking are expensive and unreliable. At the same time, it means unreasonable monotonous work. Here, automated machine vision systems provide solutions to these problems.
2 Defects of PET beverage bottles
Bottle blowing, filling, labeling and labeling, and coding are the four key processes that affect the quality of PET beverage bottles. First of all, in the bottle blowing process, high-temperature gas is blown into the preform and pressed into a bottle by a specific mold. During this process, the bottle may be deformed and crooked. In the filling process, the PET bottle will have leaking and less filling. , The cover is loosened and twisted; in the labeling and labeling process, the label will be skewed and missing; in the printing process, due to the accidental failure of the printer, the code will be missed and misprinted. Happening. Slightly in these cases will lead to unsightly appearance of the product, severely will lead to changes in the internal quality of beverages, especially like Tea beverages and dairy beverages. Several defects that affect the quality of beverage bottles are: high cap, crooked cap, broken cap, no cap, shallow weight, wrong label, no coding. Figure 1:
3 Use machine vision to realize the automatic detection of the appearance defects of PET beverage bottles
With the increasing demand for beverages and customers' requirements for product quality, more and more beverage manufacturers use automated PET bottle defect detection systems to comprehensively inspect the appearance defects of PET bottles. This method replaces the traditional manual methods to improve production efficiency and product quality, and solves the false detection and missed detection caused by uncertain factors such as low efficiency, slow speed, and subjective constraints of the inspection personnel, and achieves better 100% of products are tested online.
3.1 Overview of Machine Vision System
The machine vision system refers to capturing the image through an image pickup device (two types: CMOS camera and CCD camera), and then transferring the image to the processing unit, through digital processing, according to the pixel distribution and brightness, color and other information. Discrimination of size, shape, color, etc. Furthermore, according to the result of the judgment, the operation of the equipment on the spot is controlled.
3.2 Machine vision realizes the automatic detection scheme of the appearance defects of PET beverage bottles
This article uses the PET beverage bottle inspection system developed by Hangzhou Huafeng Automation System Co., Ltd. for the inspection of the appearance defects of PET beverage bottles. The system takes Siemens image processor as the core and combines with Siemens automation equipment to form a system with both simple digital signal interface and complex industrial network interface, allowing users to choose a system suitable for their working conditions, which is convenient and saves investment.
The basic detection process flow is shown in Figure 2, and the simple system framework is shown in Figure 3:
Figure 2 Basic detection flow chart
Figure 3 Simple system diagram
Working principle: First, the optical fiber sensor senses the bottle, then triggers the image processor to take pictures, and performs image analysis processing, and finally drives the rejection device.
3.3 Function introduction of Hangzhou Huafeng's PET bottle visual inspection system
â‘ , online presence detection, model comparison, shape inspection, position and orientation recognition, workpiece measurement, 1D / 2D code calculation, OCR / OCV.
â‘¡ The current actual detection speed of the system reaches 1500 bottles / min.
â‘¢, can accurately reject the detected defective products (through the installation of speed encoder to automatically track the speed of the conveyor belt).
â‘£ The following statistical functions can be realized and displayed on the touch screen on site (printable by installing a printer): the number and proportion of unqualified products when the unit product passes, the number and proportion of unqualified products that pass the unit time, the production of each shift The total number of products and the number of defective products detected, the total amount of products produced each month and the number of defective products detected.
⑤. It can store the detection programs of various products on the production line and can be conveniently selected through the on-site touch screen.
â‘¥ Can communicate with the computer through the Ethernet interface to realize online monitoring, online modification of the inspection program, online recording of production data, and online saving of real-time images required by users (images of qualified products and images of unqualified products).
⑦. The height of the visual inspection device can be easily adjusted according to the different products to be inspected on the production line.
⑧. The machine vision inspection system is an independent system, which can be easily accessed or withdrawn. The required hardware and software are provided by the manufacturer.
⑨ The machine vision inspection system is easy to install, maintain and disassemble.
4 Conclusion
The system has been successfully applied to the production lines of several well-known domestic beverage companies, and the effect is very good. Not only meet the user's existing needs, but also reserve a lot of functions and upgrade space for users, these functions will play a more role in future inspection tasks, solve more problems for users, save a lot of upgrade costs . Such as: printing interface, host computer communication interface, alarm interface, label detection function, speed-up function, etc. More importantly, the system can strictly control the quality of user products, reducing a lot of labor costs. With the continuous improvement of industrial automation level and the increase of labor costs, the application prospect of this system will be more broad.
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