Customer from the manufacturing industry, from the area pharmaceutical-biotechnological (RezonBio), reported the need for implementation automatic quality control system for plastic bags, whose task was to detect leaks and film defects as early as possible in the production process.

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The aim of the project was to:

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• confirmation of the effectiveness of the technology in real conditions,

• creation of a functioning inspection post,

• ensuring a clear and unambiguous presentation of the results for the operator,

• verification of which types of defects can be detected by visual methods.

Challenge:

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The bags subject to inspection were characterized by:

• multilayer film structure (2—4 layers, with different optical properties),

• the presence of integrated elements (tubes, valves, cartridges) that locally obscure the field of view,

• susceptibility to microdamages, scratches and structural stresses invisible to the naked eye,

• high geometric and material variability between batches of products.

An additional challenge was to design a solution that:

• will repeatable and independent of the subjective assessment of the operator,

• will enable quick and unambiguous quality assessment,

• will remain Ergonomic in everyday work, even with the need to manually position the bag.

Applied solution:

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We designed hybrid vision system, based on a combination of:

• industrial video cameras (5 MP),

• Dedicated lighting:

• Backlight (passing lighting),

• Frontlight (reflected lighting),

• Polarization of light (polarizing filters on the side of the light source and camera),

• image analysis algorithms.

The key element of the solution was fusion of two inspection methods:

• Backlight — for detection holes, leaks and structural defects,

• Frontlight with polarized light — for detection scratches, creases, stresses and surface defects.

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Inspection process It is carried out in a semi-automatic way. The vision system analyzes the image and indicates potential areas of damage, presenting the result of the analysis to the operator along with an estimated level of probability of occurrence of the defect (e.g. in the form of a percentage assessment). The final decision to classify the detected non-compliance as a factual and dangerous defect lies with the operator. In the long term, the solution provides the basis for full automation of defect interpretation with the development of algorithms.

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Summary:
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The implementation of our vision system enabled the rapid commissioning and full validation of the polybag quality control stand, while introducing a new standard of vision inspection support. The solution provides Repetitive and objective image analysissignificantly reducing the impact of the human factor in detecting potential incompatibilities, while maintaining an informed final decision on the part of the operator. This translates into greater stability of the process and an increase in the quality of products.

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If your company is also looking for modern quality control solutions, VisionX designs and implements advanced vision systems for various industries. We treat each project individually, adapting the technology to the real needs of the process.

Perhaps the next implementation will be yours - contact us and see how we can support the development of your production.

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