A Machine Vision Case Study

Box sorting innovative machine vision solution

Inline sorting of variable-sized boxes for mixed products is a common challenge on automated packaging lines in many production facilities.

The Problem: Multi-sized Boxes

Boxes traveling down the line needed to be sorted into one of three stackers, depending on the dimensions of the box and their coordinating labels.

The Solution: Machine Vision

We used two cameras to identify the case codes for each box and a laser to verify the dimensions by building a three-dimensional model of each box. This also detects boxes with open flaps or other irregularities.

We used an Allen-Bradley ControlLogix PLC with two Basler Gigabit Ethernet cameras, in coordination with a Hermary SL-1880 3D laser, to verify the key components on each box. The two cameras are used to identify the exact case codes for each box type as they are fed down the line. The laser system is used to verify the dimensions by building a three-dimensional model of each box as they pass under the lasers.

Cameras and laser prove highly accurate

This allows the system to not only measure the dimensions of the box, but to also detect boxes with open flaps or other irregularities. The box is sorted accordingly and the next box enters the system. If one or more parameters are violated, then a reject code is delivered, and it is separated out of the line.

The system has an identification and sorting accuracy of 99.9 percent and is capable of operating at speeds of 60 boxes per minute. It provided a consistent system of verifying boxes, and has met and exceeded all of the customer’s expectations.

The Results

The system has an identification and sorting accuracy of 99.9 percent and is capable of operating at speeds of 60 boxes per minute. The solution met and exceeded all of the customer’s expectations.

Project Details