While an automated packaging line can boost the efficiency of the operation, traditional vision-based inspection techniques are labor intensive and prone to inaccuracies, significantly reducing the effectiveness of the automation. However, innovative 3D laser sensors provide the required speed, accuracy and consistency for today’s high-volume industrial packaging lines.
What is 3D Sensor Technology?
3D sensors use laser light to digitally capture the shape of physical objects. In operation, laser sensors emit light that reflects off the surface of an object or package and then back to the sensor, which applies an algorithm to determine how much light is displaced. Based on this data, a high-density 3D point cloud of the full expanse of the object or package is generated, resulting in an exact three-dimensional replica.
When the technology is applied to an automated packaging line for inspection and verification purposes, the non-contact technology ensures that each package has been properly filled, closed and/or sealed without damage and in accordance with predetermined quality parameters.
While early 3D laser sensors were difficult to integrate and complex to use, modern 3D sensor technologies, such as the Gocator from LMI Technologies, offer smart, all-in-one scanning, measurement and control functions built into a single device, greatly simplifying automated, non-contact 3D inspection on packaging lines.
The LMI Gocator product line includes the following technologies:
Snapshot Sensors
Gocator snapshot sensors are smart 3D sensors capable of combining full-field 3D point cloud acquisition using fringe projection with 3D measurement tools for specific 3D features. These laser sensors are suitable for inline inspection applications where objects are momentarily stationary such as in robot inspection or pick-and-place operations.
Point Profile Sensors
Gocator point profile sensors are high-speed, single-point measurement devices capable of inspecting displacement in a fast-moving packaging line process. They are suitable for contour feature measurement of products or packages at very high speeds or closed-loop feedback systems. The point profile sensors are an all-in-one solution.
Line Profile Sensors
The line profile sensors measure a cross-sectional shape. Cross sections can be collected to form 3D point clouds representing discrete whole parts. A profile sensor can measure the shape of very small- to large-width objects moving at high speeds.
What sets LMI Technologies’ modern Gocator laser sensors apart from earlier 3D sensor technologies is the all-in-one functionality, which means they require no additional software or external computing devices and the built-in measurement tools are configured via a simple web server stored within the sensor’s processor.
Packaging Line Inspection Applications for Advanced Laser Sensors
There are a number of packaging line inspection applications that benefit from the use of modern laser sensor technology, including:
| Defect detection | Automated snapshot sensors provide highly accurate data, allowing them to sense and detect surface irregularities, such as shape deformations that would impact the appearance, quality or safety of a package. Because very detailed and accurate measurements are possible, they can quickly identify defects that would be missed by the human eye, helping packagers reduce defects in packaging that could result in costly waste, rework and/or product recalls. |
| Open box content verification | All-in-one, smart 3D sensors can look into containers and create a 3D point cloud of the contents, allowing them to verify contents, product count and position, shapes and height variations as packages move along the packaging line. |
| Sealed container inspection | LMI Gocator all-in-one 3D sensors can also identify height variations of sealed packages to verify proper sealing and detect any crushed or damaged areas. |
| Volume verification | Because laser sensor technology can measure and determine dimensions, they can be used to verify the volume of packages as they move along the packaging line. |
4 Benefits of Using 3D Sensors for Packaging Line Inspection
There are four key advantages to using 3D sensors, such as the Gocator from LMI Technologies, to perform automated inspections on packaging lines, including:
- Accuracy: Laser sensors provide extremely high levels of accuracy and precision, allowing them to identify packaging line defects more accurately than human vision or other machine vision-based technologies.
- High speed: 3D laser sensors offer very fast sampling rates, giving them the ability to capture thousands of profiles per second. The ability to accurately keep pace with high-speed automated packaging lines increases the overall efficiency of the operation.
- Non-contact technology: Because these 3D sensors are non-contact measurement devices, they can quickly and accurately conduct inspections without touching or damaging delicate products or packages, increasing quality and reducing scrap, waste and rework.
- Improved quality control: 3D sensors, such as the Gocator, can detect very small defects and flaws that would likely be missed by human or machine vision inspection systems at the high speeds found on automated packaging lines. The ability to continuously and accurately monitor for and identify defects will boost quality control efforts by preventing damaged or flawed products and packages from leaving the packaging line undetected. Not only does this help avoid costly recalls, but it may lead to increased customer satisfaction levels and repeat business.
Advanced 3D laser sensors, such as the Gocator from LMI Technologies, are revolutionizing packaging lines by providing high-speed, accurate inspection of packages, resulting in greater levels of operational efficiency and more consistent product quality than was previously possible. For more information on how the Gocator can boost the effectiveness of your packaging line inspection process, please contact the experts at HTE today.
