Challenge
Design a quality inspection system to ensure the correct label, and the correct quantity of labels, is present in each package.
Solution
A vision solution with a 31-megapixel GigE camera, Cognex VisionPro software, smart vision lighting, a custom conveyor, a Cognex DataMan reader, and a control box with PLC.
Story
A label manufacturer produces unique pressure-sensitive labels that are eventually molded directly into a container. The labels are printed, stacked, wrapped, and loaded into boxes for shipping. Unfortunately, some boxes shipped with incorrect or miscounted labels. The customer wanted every box inspected before shipping, and reached out to the experts at EMP.
The EMP team knew this was not a simple barcode or vision application. The customer has a variety of labels, each with a different barcode location, stack height, and packaging size. The solution had to read the barcode on top of each label stack. To keep the camera stationary, EMP used a 31-megapixel GigE camera to cover the entire 24-by-24-inch conveyor, with a large light that illuminates the whole area without having to move.
The package travels down the conveyor while a Cognex DataMan reader scans it to learn which product should be inside. That triggers the vision system to look for the correct number of label stacks by reading each stack’s barcode, and the custom program confirms that the barcode is the correct label. An image of each inspection is saved to the customer’s database for future reference. The whole solution was integrated seamlessly into the customer’s existing setup.
Looking to add an inspection system to your current setup? Contact EMP today.
