Implemented multicamera inspection for open flaps and closure defects, with automatic diversion for rework
Delivered System
Inspect box closure through shape
We implemented a multicamera inspection system that checks the external closure geometry of boxes and routes suspect packaging to rework. Dedicated lighting and complementary 2D views reveal open flaps, lifted corners, and protrusions. The analysis compares visible shapes with expected box geometry, keeping inspection focused on closure features across different printed graphics and labels. OPC UA communication carries inspection decisions to the PLC and connects them to diversion on the line. Operators receive the observed closure issue for assessment. Testing covered cardboard types, box formats, labels, defect visibility, false rejects, and diversion timing.
What we did on it...
Requirements
Defined external closure checks
We defined the inspection around visible closure defects: open flaps, lifted corners, and protrusions. Sample images established the relevant shape differences, giving the system a clear geometric reference for evaluating the external condition of each box.
Structure
Integrated camera views and lighting
We integrated complementary 2D camera views and dedicated lighting to compare packaging with expected box geometry. Trials across box formats established camera placement and illumination, keeping visible closure features central to the analysis across printed graphics and labels.
Interface
Connected inspection to rework diversion
We implemented OPC UA communication with the PLC to route suspect boxes to rework. Inspection results identify the observed closure issue for operator assessment, connecting camera acquisition and image analysis with the line's handling and diversion sequence.
Validation
Tested packaging variations and diversion
We tested different cardboard types, box formats, labels, and closure conditions under dedicated lighting. Validation covered defect visibility and false reject behavior, then checked diversion timing and PLC interaction to complete the workflow from visual inspection to rework.
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