Hello Members;
I require some assistance in building a vision system for assessing product defect. I have received a lot of biased & confusing recommendations so far from sale people.
I am considering a cost effective vision system for a bottling line that utilizes HDPE, PET bottles ranging in size from ( W X H) 1.5" x 2.5" to 4" x 7" ( 50cc to 400cc) The line speed ranges form 30-80 bottles/min. The conveyor is 4&1/4" wide with bottle positioned approximately in the middle of conveyor , thus could place the camera from 2" to 8" away from the bottle in order to capture the label in the field of vision.
Would like to be able to 1) detect presence/absence of label and lot/exp ( lot/exp are printed by a coder either on the label itself in a predetermined space or on the shoulder of the bottle) , 2) label alignment ( crooked label) 3) lid/cap presence on bottle, and lid/cap alignment. I have been told that depending how accurate I want to detect a crooked label or cross threaded cap would require a much higher resolution camera. I think 5 pixels is approx. 1.3mm. Is that to precise to detect. if so, could accept 2-3mm label misalignment.
3) If it could detect ripped, damaged or wrinkled labels that would an added bonus but don't want to add this feature if it greatly escalates the cost.
If above defects are detected, would like to reject from conveyor via some sort of pneumatic blast of air. I think in some systems a PLC is not required and one can have the signal directly from the vision system of "NG" product trigger a 24v response sent to the pneumatic valve close to the camera, thus perhaps not requiring a timer or encoder?
Would like the system to be easy to set-up and change for different products.
Is it feasible to set-up a in-expensive system to do this? There are many used systems and components on ebay at greatly reduced cost. Each Company ( Omron --ZFX c20/25, FLV, Keyence IV-H series, Cognex Insight-2000 or checker 4G system) looks to have all-in-one models that have very easy user interfaces, are easy to install and set up as there is automation in the software for focusing and lighting etc.... Just not sure if they are capable of achieving the above defect screening. I am open to more advanced systems if they are not to difficult to set-up and use. If you could give me some recommendations of model(s) controller, cam, light source that would be capable of achieve the above would be greatly appreciate
Thank-you for your help
Cam 123
