The challenge
On the packaging line, two separate machine vision systems were operational: one for checking dents and seam integrity, and one for the presence of labels on the can. Both systems utilized aging technology for which service support – both locally and remotely – was becoming increasingly difficult to guarantee.
The producer processes up to 1,000 cans per hour, with each can being fitted with four labels: a front label, back label, hologram label, and picture label. The placement of all these labels, along with the geometric integrity of the cans themselves, had to be reliably and reproducibly checked. Manual inspection was not an option at this production speed.
The solution
Vision Partners designed an integrated machine vision inspection setup that combines both inspections into a single system, built around the existing can rotation mechanism on the production line. Two image acquisition units are simultaneously active during the can's rotation. Image processing is performed using HALCON, the advanced machine vision software from MVTec, for which Vision Partners is a certified integrator.
The system consists of:
- Line-scan camera with LED lighting checks the presence and positioning of all four labels (front, back, hologram, and picture label) and reads the 2D data code from each placed label for archiving.
- Area-scan camera with backlight illumination detects dents in the tin and checks the integrity of the top seam.
- Encoder measure the precise rotation speed of the can for reliable image acquisition by the line-scan camera.
- Siemens S7 PLC with ejector automatically rejects disapproving looks upon detecting a deviation.
- Industrial PC in a Rittal control cabinet: processes all images in real-time with HALCON and saves inspection results and images in batches for full traceability.
- HMI touchscreen offers operators a clear main screen with the latest inspection result, camera status, and a logbook that can be quickly filtered by batch, timestamp, or result; settings are secured with user account management.
For the mechanical integration, Vision Partners collaborated with the specialized machine builder responsible for the packaging line, including the correct positioning of the cameras and the encoder in the 3D drawing of the line.
As an official distributor of Hikrobot in the Netherlands, Vision Partners not only supplies the hardware but also guarantees direct support and availability of the cameras and associated components.
The result
The new system replaces two aging inspection setups with one integrated, fully turn-key solution delivered on-site. All four label positions are automatically inspected, while simultaneously assessing the geometry of each can – dents and seaming – at a production speed of 1,000 cans per hour. Rejected cans are immediately ejected without operator intervention.
The integration of Hikrobot hardware and HALCON image processing offers three concrete advantages: inspection stability improves as the system provides consistent and objective assessments at any production speed, manual labor for operators is significantly reduced due to fully automated inspections, and traceability increases as images and measurement results are stored per batch and can be easily retrieved via the HMI.
The system is built on Microsoft Windows 11 IoT Enterprise LTSC, with a 10-year lifecycle, ensuring long-term and stable operation. Vision Partners provides the complete delivery, including Factory Acceptance Test (FAT), user documentation, and remote support via a secure connection – so the producer can be helped quickly at any time.
