Case layout verification and counting
The open case is imaged from above before sealing. The layout template is aligned to the case position and angle, a cap is located in each cell and the items are counted; a case with a missing or misplaced item is diverted.
Counted quantity, empty cell and alignment angle go to the operator display. A complete case closes and is taped; a case with a missing product is pushed onto the side line before sealing.
- 01 Infeed
- 02 Acquire
- 03 Layout
- 04 Count
- 05 Decide
The filled case arrives at the station on the roller line with its flaps open.
- Counted
- —
- Empty cells
- —
- Case angle
- —
Scenes are illustrative simulations; they are not customer references or performance guarantees.
Need
Case rotation and shadows from open flaps change the apparent positions of bottle caps. The counting template must align with the case and distinguish an empty cell from its neighbouring product.
Solution approach
A photo-sensor triggers an overhead camera to image the open case under ring lighting. The template aligns with the case position and angle; a cap is located in each cell and the detected positions are compared with the expected layout.
Process steps
- 01
Infeed
The filled case arrives at the station on the roller line with its flaps open.
- 02
Acquire
The photo-sensor triggers; the ring light strobes and the case is imaged from above.
- 03
Layout
The layout template is aligned to the position and angle of the case.
- 04
Count
A cap is searched for in each template cell; the ones found are counted in turn.
- 05
Decide
The counted quantity is compared with the expected layout.
Related applications
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